Remove & Install Hydraulic Hammer
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Hammer may roll over when being removed from carrier. The hammer may cause personal injury. Only use a skilled operator to position the carrier for hammer removal. |
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Hoses are under high pressure. Pressurized oil can cause personal injury. Release oil pressure before opening hose connections. Wait ten minutes for oil pressure to drop and release oil pressure again before opening hose connections. |
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1. Position hammer horizontally on the floor and remove the tool.
2. Disconnect hoses (5). Plug the hoses and the hammer and outlet ports.
3. Remove mounting bracket washers (2) and nuts (1).
4. The carrier, with mounting bracket (4) still attached, can be moved aside.
NOTE: The following steps are for the installation of the hammer.
5. Install mounting bracket (4), mounting bracket bolts (3), washers (2), and nuts (1).
6. Torque bolts (3) to 340 N·m (250 lb ft).
7. Connect hoses (5).
Disassemble & Assemble Hydraulic Hammer
Start By:
Remove hydraulic hammer
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The hammer may roll during removal of side plates. The rolling hammer may cause personal injury. Secure hammer from rolling before sideplate bolts are removed. |
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Do not disassemble hammer before releasing gas pressure from accumulators. Pressure can propel objects and cause serious injury. Release pressure before disassembling accumulators |
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1. Remove hex nuts (5) and threaded rods (1) (if equipped). Remove bolts (3), and lock washers (4).
2. Remove sideplates (2).
3. Remove buffer (7) and locating pins (6) (if equipped).
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Do not disassemble hammer before releasing gas pressure from accumulators. Pressure can propel objects and cause serious injury. Release pressure before disassembling accumulators |
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4. Set the hammer onto FT-2639 hydraulic Hammer Stand by removing plug (8) and O-ring (9) from low pressure accumulator (10) and installing a eyebolt in the hammer. The weight of the hammer is 130 kg (290 lbs)
5. Release oil pressure from hammer by carefully opening pressure test ports (11).
6. Remove lifting ring from low pressure accumulator installed in step 4.
7. CAREFULLY loosen the filling plug (12) and bleed off the nitrogen gas.
8. When nitrogen gas is completely released from low pressure accumulator, remove plug (12) and Usit-ring (13).
9. Repeat steps 7 & 8 for high pressure accumulator (16) using plug (14), O-ring (15), fill plug (17) and USIT-ring (18).
10. Remove bolts (19) and lock washers (20).
11. Remove low pressure accumulator assembly (10).
12. Remove high pressure accumulator assembly (16).
13. Set the low pressure accumulator on the assembly stand or fix it on a vise so that the accumulator is upside down.
14. Remove O-ring (21).
15. Remove bolts (22).
16. Remove accumulator bottom (23) and membrane (24).
17. Set the high pressure accumulator on the assembly stand or fix it on a vise so that the accumulator is upside down.
18. Remove O-ring (25).
19. Remove bolts (26).
20. Remove accumulator bottom (27) and membrane (28).
21. Remove rubber rings (29) and locking plates (30).
22. Mark each tie rod (31) and its nut (32) as pairs. Mark nut to show top side.
23. Remove tie rods (31) crosswise.
24. Insert 8 mm bolt into nut (32) and pull nut (32) out. Do not turn nuts (32) upside down.
25. Remove washer (33) from tie rod (31).
26. Remove valve body (34).
27. Position valve body (34) on a flat surface and turn it upside down to remove distributor and its accompanying parts.
28. Remove steering bushing (36), distributor (35) and assembly ring (37).
29. Remove O-rings from steering bushing (36).
30. Remove seal assembly from inside steering bushing (36).
31. Remove O-rings (40 and 42) from cylinder (41).
32. Remove guide pin (43).
33. Lift out piston (44).
34. Remove cylinder (41).
35. Remove wiper (45) and seal assembly (46) from cylinder (41).
36. Remove thrust ring (47).
37. Remove upper tool bushing (48).
38. Remove guide pin (49).
NOTE: The following steps are for the assembly of the hydraulic hammer.
39. Check all parts for wear or damage.
If necessary, use fine emery cloth or grinding agent. Clean and oil all parts.
40. Install guide pin (49).
NOTE: Coat the outside of thrust ring (47) and upper tool bushing (48) with anti-seize compound.
41. Install upper tool bushing (48).
42. Install thrust ring (47).
43. Install wiper (45) and seal assembly (46) in cylinder.
44. Apply MoS2 spray on the contact surface between front head and cylinder.
45. Install cylinder (41) into the front head so that the guide pin in the front head aligns with the respective hole in the cylinder(41).
46. Oil piston (44) and install into cylinder (41).
47. Install O-rings (40 and 42).
48. Install guide pin (43).
49. Lubricate and install O-rings (38) and seal assembly (39) on steering bushing (36).
50. Install distributor (36) into steering bushing (37).
51. Install assembly ring (38) on to steering ring (37) and distributor (36).
52. Distributor (36) must move freely inside bushings.
53. Position valve body (34) on a flat surface and install steering bushing (36). distributor (35) and assembly ring (37). Be sure to install assembly with grooved end of distributor (36) exposed.
54. Apply MoS2 spray on the contact surface of valve body and cylinder.
55. Install valve body (34) so that the guide pin in the cylinder aligns with the respective hole in the valve body.
56. Use a plastic hammer to seat the valve body(34).
57. Use 4C-4736 Liquid Penetration Kit or 4C-4735 Magnetic Particle test Kit to check for cracks in the tie rod threads or under the head. If cracks are detected, change the tie rod and its nut. Also change the diagonal tie rod and nut.
58. Clean all tie rods and grease threads and the contact surface of tie rods and the valve body.
59. Spread cold-galvanizing spray on the part of tie rod which goes inside the front head.
60. Install tie rods (31) and washers. Washers must be installed with chamfer facing up.
Check that each tie rod (31) has the right nut as its pair. Do not turn nuts (32) upside down.
61. Use a torque wrench to tighten the rods crosswise to the torque of 70 N·m (52 lb ft).
62. Tighten an additional 60° with a socket and handle extension.
63. Install locking plates (30) so that the tie rods can not loosen.
64. Install rubber rings (29).
65. Set the high pressure accumulator bottom (27) on the assembly tool, or fix it on a vice.
66. Put a NEW membrane (28) in place. Apply silicone grease on the gas side of the membrane (28) and on the accumulator cover.
67. Install accumulator cover onto accumulator bottom (27).
68. Grease threads of hexagonal socket bolts (26).
69. Install lock washers under bolts (26).
70. Torque bolts (26) to 60 N·m (52 lb ft).
71. Install O-ring (25).
72. Install NEW Usit-ring (18) and existing filling plug (17).
73. Set the low pressure accumulator bottom (23) on the assembly tool, or fix it on a vice.
74. Put a NEW membrane (24) in place. Apply silicone grease on the gas side of the membrane (24) and on the accumulator cover.
75. Install accumulator cover onto accumulator bottom (23).
76. Grease threads of hexagonal socket bolts (24).
77. Install lock washers under bolts (24).
78. Torque bolts (24) to 60 N·m (52 lb ft).
79. Lubricate and install O-ring (21).
80. Install NEW Usit-ring (13) and existing filling plug (12).
81. Apply MoS2 spray on the contact surface of valve body (34) and accumulators).
82. Lower the accumulators into place using eyebolt.
83. Grease threads of hexagonal bolts (19).
84. Install lock washers (20) under bolts (19).
85. Torque bolts (19) to 70 N·m (52 lb ft).
NOTE: The following steps are for the installation of the sideplates.
The outside of the upper mufflers are adhesive. During normal service, there is no need to remove the upper muffler from the side plates. If you need to replace the upper muffler, make sure that the sideplates (2) are clean and dry. Peel the protective film from the upper muffler and attach it into the sideplates. (If equipped)
86. Place one sideplate (2) on a level surface.
87. Install locating pins (6) (if equipped).
88. Grease threads of bolts (3) and threaded rods (1) (if equipped).
89. Place hammer onto side plate(2). Place other sideplate on top of hammer. Compress parts together, if equipped with a muffler.
90. Align sideplate mounting holes to carrier before tightening bolts.
91. Torque bolts to 250 N·m (184 lb ft).
92. Install buffer (7) (if equipped).