Testing and Adjusting

• Pre-delivery systems set up

• Relief Valve Crack Point

• Transducer Tests

• Basic Trouble Shooting

0

HAMMER DELIVERYSERVICE RECORD

DLR CODE HAMMER MODEL SERIAL NO. HOURS DELIVERY DATE / /

CARRIER MAKE MODEL SERIAL NO. WEIGHT HOURSIDENTIFICATION:

INSTALLATION MOUNTING BRACKET: CAT DLR CONNECTING HOSES: CAT DLR INFORMATION:

TOOLS: BLUNT CHISEL MOIL OTHER TYPE

APPLICATION: QUARRY DEMOLITION TUNNELING OTHER

TEST DATA

NOTE: ALL TESTING MUST BE DONE AT MAX. ENGINE RPM,MAX. POWER LEVEL AND MAX. WORK MODE.

HAMMER DATA: Accumulator charge (models H115s to H195) BAR/PSI Low pressure accumulator charge (models H45 to H100) BAR/PSI High pressure accumulator charge (models H45 to H100) BAR/PSI

Oil flow to hammer (at operating pressure) LPM/GPM Operating pressure at hammer inlet (models H45 to H100) BAR/PSI Low pressure circuit (models H45 to H100) BAR/PSI Pressure in the return line (back pressure ) BAR/PSI Line relief valve setting (cracking pressure) BAR/PSI Main relief valve setting of carrier BAR/PSI Hydraulic oil temperature during test ° C / ° F

MACHINE DATA: Flow regulator valve for hammer YES NO Oil cooler on machine YES NO Oil filter in hammer return line YES NO

Testing and Adjusting Hammer Delivery Service Record

• Keep a copy in machine history folder for future reference

• Can be used to speed up trouble shooting process

• Run all tests at:

High Idle

Highest Power Mode

Attachment Priority Work Mode

Hydraulic Oil at Operating Temp.

SEE SERVICE MANUALS FOR FULL FORM. (TESTING AND ADJUSTING SECTION)

Critical Information

Testing and Adjusting Hydraulic Flow TestBackhoe (H63 - H100)

Flow Pressure Back Pressure Oil Temperature(GPM) @ Flow Meter

Free flow 5001000150018002000230024002500

Test Purposes:- Verify flow at pressure- Verify back pressure in hammer return line- Verify relief setting in hammer circuit

Testing and Adjusting Hydraulic Operating TestBackhoe (H63 - H100)

Test Purposes:- Verify average operating pressure to specification- Confirm pressure adjusting valve set properly

Both hammer test ports are 4BSPP

Testing and Adjusting Hydraulic Flow TestExcavator (H115s - H195)

Flow Pressure Back Pressure Oil Temperature(GPM) @ Flow Meter

Free flow 5001000150018002000230024002500

Test Purposes:- Verify flow at pressure- Verify back pressure in hammer return line- Verify relief setting in hammer circuit

Flow Meter

Back Pressure Gauge

Testing and Adjusting Hydraulic Operating TestExcavator (H115s - H195)

Test Purposes:- Verify average operating pressure to specification- Confirm pressure controller set properly

Pressure Gauge

Test port is 4BSPP

Testing and Adjusting Auxiliary Circuit Flow Test

20

04

00

60

08

00

10

00

12

00

14

00

16

00

18

00

20

00

22

00

24

00

26

00

28

00

30

00

32

00Pressure (psi)

0

20

40

60

80

100

Flo

w (

gp

m)

Flow (gpm)

Flow Test Cracking Point

Flow test helps verify that the relief cracking point is higher than the combination of:

Hammer Operating Pressure + Return line back pressure + a “Safety” Margin.

Testing and Adjusting Transducer Test

SAFETY MARGIN

CORRECT

RELIEF SETTING

PEAK PSI

AVERAGE OPERATING PRESSURE

30

00 P

SI

PR

ES

SU

RE

0

0 1 2 3 4 5TIME

PEAK PRESSURE IS HIGHER THAN RELIEF

INCORRECT

RELIEF SETTINGPEAK PSI

AVERAGE OPERATING PRESSURE

30

00 P

SI

PR

ES

SU

RE

0

0 1 2 3 4 5TIME

PROBLEMS: - OVERHEATING - SLOW HAMMER

Testing and Adjusting Basic Trouble Shooting

Hammer Doesn’t Start

Irregular but Full Energy Blows

No Energy, Poor Operation

•Piston in Lower Brake•Relief Valve Opens•Too Much Back Pressure in Return Line•Internal Problem (Check Valves, Piston, Tie Rods)

•Not Enough Feed Force from the Carrier•Relief Valve Opens•Dirt in Hammer•Internal Problem (Check Valves, Piston, Tie Rods)

•Incorrect Working Method•Relief Valve Opens•Incorrect Pressure Control Valve Setting•Nitrogen Charge Lost•Tie Rods Loose

Testing and Adjusting Basic Trouble Shooting

Low Blow Frequency

Oil Warms Up

Hammer Bleeds Oil

Hammer Moves in Housing

•Relief Valve Opens•Oil Overheating•Oil Viscosity is too Low•Back Pressure too High•Low Flow from Pump•Internal Leak in the Hammer or Hydraulic Circuit•Nitrogen Charge Lost

•Relief Valve Opens•Too Low Cooling Capacity•Too Low Oil Viscosity•Faulty Hydraulic Installation•Internal Leak

•Check Hose Connections•Reseal Hammer

•Replace Wear Plates

1. Carrier SystemElectrical.Relief setting.Flow setting.Filter.

2. Hydraulic KitQuick coupler failure.Damaged or pinched hose.Ball valve closed.

3. Hammer

Three potential areas for a hammer problem:

1. Eliminate the carrier as a problem source.

2. Eliminate the hydraulic kit as a problem source.

INSTALLNG A FLOW METER:

Eliminates two of the three possible areas for problem.