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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
Caterpillar Impact Products Ltd.Caterpillar HammersMaintenance“KEY to SUCCESS”YESRead the manuals --- It’s important!Hammer Components are machined with closetolerances.-- Oil components before assembly-- Use solvent tank and Krokus cloth to clean-- Do not use steam cleaner on internal parts.www.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersMaintenanceOperator Requirements• Properly grease hammer• Tighten loose connections in hydraulic system• Inspect tool retaining pins• Remove burrs from retaining pin groove on tool• Check lower tool bushing for wear• Check top and side buffers for cracks and wear• Check condition of wear parts, hydraulic connections etc.DailyWeeklyMonthlywww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersGREASING INTERVAL■Every two hours; hourly in extreme conditions■10-15 strokes from the grease gun Adapt interval and amount according to greasequality, 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 lowestambient temperature■Grade NGLI number 0-2■Water resistantGREASING OF TOOL■Hammer must be standing upright againstthe tool■Check that grease goes between tooland bushings■Do not over greaseLubrication Guidewww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersRESULTS of IMPROPER GREASINGWithout proper down force grease WILL cause premature seal failure.Improper GreasingToolPistonGrease blows up pass sealsANY and ALL hydraulic hammers.www.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersAutomatic Lubrication System - AutolubeGrease Pump activated by electrical signalfrom hammer foot switch or pressure switch,supplies grease to hammer tool bushings.Grease amount is adjusted by dials insidepump/motor housing. Greasing cycle isadjusted by both the ON and OFF dials .• BLUE dial controls OFF time in cycle• RED dial controls ON time in cycleCycle active only when hammer is operating.Pump/motor housingwww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersAutolube - Small Hammers (H45-H100)Port located on frontAuto-LubeConnectionAir channel for underwater applicationsSMALL HAMMERS (H45-H100C)Manual Grease Points Autolube Connection Air ConnectionModel # points location port size location port size location port sizeH45/H45s 1 LH 1/8" BSPPH50/H50s 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPPH63/H63s 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPPH70/H70s 2 LH 1/8" BSPPH90C/H90Cs 2 LH 1/8" BSPP Front 3/8" BSPP Back 1/2" BSPPH100/H100s 2 LH 1/8" BSPP Front 1/4" BSPP Back 1/2" BSPPside of lower body.www.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersManual Grease Points Autolube Connection Air ConnectionModel # points location port size location port size location port sizeH115s 2 LH 1/4" BSPP Return-RH 1/4" BSPP Supply-LH 1/4" BSPPH120Cs 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Supply-LH 3/8" BSPPH130s 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Return-RH 3/8" BSPPH140s 1 RH 1/4" BSPPH160s 1 RH 1/4" BSPPH180s 2 LH 1/4" BSPP Supply-LH 3/8" BSPP Return-RH 1/2" BSPPAutolube - Large Hammers (H115s-H180s)Port is located on upper valve housingnext to the supply or return port - seechart below .Port identifications:• ‘G’ indentifies autolube port.• ‘A’ indentifies ‘Air’ channel port.Note: For H140s & H160s, Autolube adaptsexternally at the manual grease port. Externalguarding is required to protect line and fittings.See Notewww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersInstallation: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.Autolube - Important Reminderswww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersMaintenanceOperator RequirementsGrind burrs off edgesCheck For Burrs in tool retaining pin groovewww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar HammersMaintenance• Once a year or between 600-1000 machine hours• Replace all seals and accumulator membranes.• Inspect internal components for wear.• Replace warning and safety labels.• Inspect tie rods.Inspect and replace according to specifications:• Tool bushings• Tool retaining pins• Tool• Thrust Ring• Buffers H115s - H180s• Wear Plates H115s - H180s• 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 hosesAnnual ServiceReplace Wear ItemsCheck Systemswww.oto-hui.com [...]... Products Ltd www.oto-hui.com Caterpillar Hammers Analysis of Wear Component Failure Membranes and Seals Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membranes and Seals Inspection of components can assist in analyzing cause of failure and /or operating conditions Membrane Seals Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membrane - Failure Modes 1 INCORRECT... FIRING Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membrane- 1 Installation • Membranes are identified by a manufacturing data and stamped “gas side” for proper installation • Installed and operated upside down changes contact position with accumulator screen “Gas” side Improper installation Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membranes - 2 Loss... low or fatigued • Internal to hammer Piston seizures Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membrane - 5 Contamination Contamination of oil will puncture membrane Foreign particles from: • Quick couplers • Exposed hose end fittings • Dirty oil Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Membrane - 6 Blank Firing Screen contact surface Membrane travels... is lost, and membrane allowed to contact screen Screen Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Seals - Temperature Inspection of seals can indicate symptom of failure Seal color changes from cycle time and oil temperature New 0 hours 1000 hours Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Seals - Heat Failure Solve the Problem Heat failure is caused... application Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Piston Impact Area • • • • Piston damage 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 Common failure of pirate tools Tools with a deformed or chipped top edge will cause piston failure Caterpillar. .. www.oto-hui.com Caterpillar Hammers Blank Firing 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: - Worn lower tool bushing - Worn retaining pins - usually with chisel tool Retainer pin fatigue Caterpillar. .. www.oto-hui.com Caterpillar Hammers Fatigue -1 Common Failure Common Failure Beach marks Starting point 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 “Beach mark” patterns - Semi circular marks around failure point Caterpillar Impact Products Ltd www.oto-hui.com... caused by: - Prying with tool - Wrong working angle • High lip formation occurs in or near lower tool bushing Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar HammersTOOL TIP Mushrooming Mushroom effect Hammering in one spot too long - No tool penetration - Produces higher heat loads on tip Wrong working method To small hammer for application Chipped Edge Chipping caused by: - Improper... = 78,624,000 cycles Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers Wear Components Expected Life per Hour Usage Estimates DESCRIPTION TOOL TOOL RETAINER PIN(S) LOWER TOOL BUSHING THRUST BUSHING UPPER TOOL BUSHING SEAL KIT MEMBRANE(S) TIE RODS HOUSING WEAR PLATES SIDE PLATES MODELS H63-H100 HOUSING MODELS H115s-H195 BUFFER ASSEMBLY H115s-H195 BUFFER PADS H115s-H195 10 50 100 200... 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 Caterpillar Impact Products Ltd www.oto-hui.com Caterpillar Hammers #1 Failure caused by Operators #1 Failure caused by Operators BENDING.1 . closetolerances .-- Oil components before assembly -- Use solvent tank and Krokus cloth to clean -- Do not use steam cleaner on internal parts.www.oto-hui.com Caterpillar. MODELS H63-H100HOUSING MODELS H115s-H195BUFFER ASSEMBLY H115s-H195BUFFER PADS H115s-H195Expected Maxwww.oto-hui.com Caterpillar Impact Products Ltd.Caterpillar