Manual Operador Martillo Baker

HYDRAULIC BREAKER

CAL-225 CAL-450 CAL-550 CAL-750

CAL-1000 CAL-1200 CAL-2200 CAL-3200 CAL-4500 CAL-6000 CAL-8000

CAL-11000

Table of Contents

CONSTRUCTION ATTACHMENTS, INC. C 4

CONSTRUCTION

AT TACHMENTS

LC 4

CONSTRUCTION

AT TACHMENTS

L

OPERATOR’S MANUAL

(REV: 21 APR, 2003)

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1. SERVICE WARRANTY REGISTRATION CARD…………………………………………………. 4 2. SPECIFICATIONS ……………………………………………………… ……………………………. 5 3. SAFETY………………………………………………………………………………………………… 6

3.1 Safety Instructions 3.2 Machine Signs (Decals)

4. BREAKER NOMENCLATURE…………………………………………………………………………. 10

4.1 Main Structure 4.2 Principles of Operation

5. REMOVAL & INSTALLATION of HYDRAULIC BREAKER………………………………… 13

5.1 Removal of Hydraulic Breaker 5.2 Storing

6. OPERATION …………………………………………………………………………………………… 15

6.1 Proper Way of Operation 6.2 Precaution for Operation 6.2 Lubrication 6.4 Working in High-Temperature Conditions 6.5 Working in Low-Temperature Conditions

7. CHISEL ………………………………………………………………………………………………… 24

7.1 Replacement of The Chisel 7.2 Essential Points in Use 7.3 Chisel Shapes 7.4 Cause of Tool Damage

8. SERVICE ………………..…………………………………………………………………………….. 28

8.1 Inspection & Maintenance 8.2 Bolts 8.3 Gas Pressure and Charging Nitrogen Gas 8.4 Wear Parts 8.5 Front Cover 8.6 Working Pressure 8.7 Oil Temperature 8.8 Accumulator 8.9 Oil Leakage 8.10 Oil Contamination 8.11 Charging The Gas in the Head Cap 8.12 Charging The Gas in the Accumulator

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8.13 Checking The Gas Pressure in the Head Cap 8.13 Checking The Gas Pressure in the Accumulator

9. INSTALLATION of HYDRAULIC BREAKER……………………………………………………… 36 9.1 General View of Breaker Installed to Base Machine 9.2 Precautions During Installation 9.3 Hydraulic System 9.4 Proper Input Oil Flow 9.5 Adjusting Impact Blow Rate 9.6 Hydraulic Pipe Lines and Controls

10. DISASSEMBLY & REASSEMBLY………………………………………………………………… 41

10.1 Dissembling 10.2 Assembling 10.3 Inspection 10.4 Repairing Parts

11. MAINTENANCE PERFORMED by The OPERATOR…………………….………………… 54 12. TROUBLE SHOOTING……………………………………………………………………….. 55

12.1 Malfunctions 12.2 Oil Leakage 12.3 Poor Operation of Breaker

13. TORQUE………………………………………………… …………………………………… 59

13.1 Through Bolts 13.2 Bulk Cap Bolts 13.3 Accumulator Body Parts 13.4 Accumulator Cover Parts

14. COMPLETING the SERVICE WARRANTY REGISTRATION & SUBMITTING

WARRANTY CLAIMS .…………………………………………………………………………… 66 15. WARRANTY POLICY………………………………………………………………………… 69

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1. SERVICE WARRANTY REGISTRATION CARD The SERVICE WARRANTY REGISTRATION CARD must be completed by the dealer and signed by the owner when the hydraulic breaker is delivered. A copy of the form must be given to the owner. Make sure it is filled out completely. Write the correct information for your Construction Attachments Hydraulic Breaker in spaces below: Always use the serial number of the machine when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. Hydraulic Breaker:

Model

Serial Number

Hydraulic Breaker Dealer: Name ____________________________

Address Phone

This Operation Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Construction Attachments Hydraulic Breaker. WARNING READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR HYDRAULIC BREAKER. If you have any questions, see your Construction Attachments Hydraulic Breaker Dealer.

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2. SPECIFICATIONS

FEATURE CAL-225 CAL-450 CAL-550 CAL-750 CAL-1000 CAL-1200 CAL-2200

Operating Weight (lbs)

198 276 514 633 944 1,160 1,830

Overall Length (in)

38.2 49.2 53.1 62.2 72.0 74.8 87.4

Chisel Size (Diameter x Length, in) 1.77 x 21.6 2.24 x 25.6 2.76 x 28.7 2.76 x 28.7 3.15 x 35.4 3.54 x 37.4 4.13 x 41.7

Pressure Relief Setting (psi)

2,500 2,500 2,500 2,500 2,500 2,500 3,000

Pressure Relief Setting (kg/cm2 )

475 175 175 175 175 175 210

Working Pressure (psi) 1,280 - 1,706 1,280 - 1,706 1,280 - 1,706 1,422 - 2,275 1,564 - 2,417 1,706 - 2,417 1,706 - 2,417

Working Pressure (kg/cm2 )

90-120 90-120 90-120 100-160 110-170 120-170 120-170

Oil Flow Requirement (gpm)

3.7 - 6.6 5.3 - 10.6 7.9 - 15.8 10.6 - 18.5 13.2 - 23.8 15.8 - 26.4 23.8 - 34.3

Blow Rate (bpm) 650 - 1,500 500 - 1,200 500 - 1,200 400 - 1,100 400 - 900 400 - 900 400 - 800

Head Cap Nitrogen Pressure

FEATURE CAL-3200 CAL-4500 CAL-6000 CAL-8000 CAL-11000

Operating Weight (lbs)

2,514 3,660 4,631 5,689 8,379

Overall Length (in)

91.7 112.0 120.0 127.2 143.7

Chisel Size (Diameter x Length, in)

4.92 x 47.2 5.31 x 51.2 5.51 x 55.1 5.91 x 57.1 6.89 x 66.9

Pressure Relief Setting (psi)

3,000 3,000 3,000 3,000 3,000

Pressure Relief Setting (kg/cm2 )

210 210 210 210 210

Working Pressure (psi)

1,849 - 2,560 1,849 - 2,560 1,849 - 2,560 1,849 - 2,560 2,133 - 2,560

Working Pressure (kg/cm2 )

130-180 130-180 130-180 130-180 150-180

Oil Flow Requirement (gpm)

34.3 - 52.8 42.2 - 58.1 47.5 - 63.4 52.8 - 68.6 68.6 - 84.5

Blow Rate (bpm)

400 - 700 400 - 700 350 - 650 300 - 600 270 - 500

Head Cap Nitrogen Pressure

Accumulator Gas Pressure - 780 - 850 psi (55-60 kg/cm2 )

BREAKER MODELS

140-200 psi (10-14 kg/cm2 )

BREAKER MODELS

140-200 psi (10-14 kg/cm2 )

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3. SAFETY 3.1 SAFETY INSTRUCTIONS

GENERAL SAFETY

• Safety is the responsibility of the OPERATOR. Construction Attachments hydraulic breakers are designed to give maximum safety, but no machine design can protect an operator from carelessness.

• Read this manual carefully before attempting to operate the hydraulic breaker.

• Untrained operators and failure to obey warnings can cause injury or death.

• Safe operation requires a qualified operator.

• Check the rules and regulations regarding the use of this equipment at your worksite. The rules may

include an employer’s work safety requirements. Regulations may identify a hazard such as an underground utility line.

• For an operator to be qualified, he/she must not use drugs or alcohol that could change his/her alertness

or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he/she can safely operate a machine.

• Operational training must consist of demonstrations and verbal instruction. Your Construction

Attachments dealer can provide this training before the hydraulic breaker is placed into service.

• The new operator must start in an area without bystanders and use all of the controls until he/she can control the excavator with the hydraulic breaker safely under all conditions in the work area.

• ALWAYS wear protective glasses, gloves, clothing, shoes, hearing protection and helmet when

operating breaker. This includes both the operator as well as workers in the immediate area.

ASSEMBLY/DISASSEMBLY SAFETY • When transporting the carrier unit with the breaker attached, refer to the host machine’s safety

regulations regarding the safe transport of this equipment. • When attaching the hydraulic breaker, use an assistant that has been instructed by the host machine

driver. All directions, signals etc. must be agreed to beforehand.

• The breaker is heavy and difficult to move. Only the carrying lug provided should be used for transporting.

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• The hydraulic breaker should only be attached to host machine with sufficient load capacity. If the host machine is too light, it may become unstable under load and tip over.

• Do not touch any parts when the boom is moving. • Never use your fingers to check for hole alignment.

• Collect any oil that leaks out and dispose of it properly.

OPERATIONAL SAFETY

• When leaving the host machine, lower the breaker to the ground and turn the engine off.

• DO NOT attach a cable or sling to the breaker to hoist a load. Doing so is extremely dangerous.

• Remove the chisel before transporting the breaker.

• Keep all people and equipment away from the breaker during operation. Debris flying from the breaker can cause serious injury.

• DO NOT use the breaker for under water applications unless the breaker has been properly adapted for

that application.

• DO NOT fire the breaker on the same spot continuously for more than (1) minute. Damage to the internal components of the breaker can occur.

• DO NOT operate the breaker with the hydraulic cylinders on the host machine fully extended.

• DO NOT touch the breaker. During operation, the hydraulic oil becomes very hot.

• Check the oil temperature regularly. Hydraulic oil temperature must never exceed 176 0F. If higher

temperatures are measured in the tank, an oil cooler must be installed.

• At temperatures lower than -40 F, the hydraulic breaker should not be put into operation with cold hydraulic oil as the seals in the hydraulic breaker may be damaged. Allow the engine and hydraulic system to warm up before operating the hydraulic breaker.

• Stop breaking immediately if anyone moves into the danger area, which is much larger for breaker

operation than for other operations due to the risk of flying debris.

• DO NOT fire the breaker unless the breaker and host machine are in a stable working position.

• Refer to the manufacturer’s safety regulations pertaining to the safe operation of the carrier.

• DO NOT use the breaker to lift or transport loads.

• DO NOT use the breaker as a prying or chopping tool.

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• Drive the tool slowly into the material being broken so it doesn’t get stuck.

• If equipped for underwater use, make sure the compressor is set to deliver air pressure that is

approximately 22 psi higher than the water pressure.

MAINTENANCE SAFETY

• Check that there is sufficient hydraulic oil in the hydraulic reservoir and that it is not contaminated.

• Check all hydraulic hose fittings and fasteners to ensure they are properly tightened.

• Check the pressure relief valve on the hydraulic system.

• Do not run any hydraulic lines through the driver’s cab.

• Grease the shank part of the chisel.

• Be careful when replacing the chisel. Internal pressure in the breaker may cause the chisel to move suddenly.

• DO NOT stand in front of the chisel when filling the accumulator or head cap with nitrogen.

• BE SURE to release all of the nitrogen pressure from the system before attempting any repairs.

Removing the head cap under pressure is EXTREMELY DANGEROUS.

• DO NOT charge the gas cushion chamber with anything other than nitrogen.

• Only use approved hydraulic oils of the proper viscosity that are specified by the host machine manufacturer.

• Always wear protective glasses and a hard hat when replacing a chisel. Metal splinters may chip off

when the spring dowel sleeves are hammered out.

• DO NOT use your fingers to check alignment of the recesses on the chisel to the slots for the retaining bars.

STORAGE SAFETY • If not used for long periods, the breaker must be stored vertically, with the bore for the tool facing

upward. Storing the breaker on its side could deform the internal seals over time, making them ineffective.

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3.2 MACHINE SIGNS (DECALS)

REFERENCE IMAGE CONTENT SIGNS

Hearing protection must be worn. Head wearing ear protection.

Consult manual for proper service

procedures. Technical manual.

Keep away from breaking area

while the breaker works.

A working breaker with diagonal

slash.

Inject grease into the hole with

grease gun periodically. Grease gun.

"HIGH PRESSURE" gas is present

that must be relieved prior to

disassembly.

Accumulator.

Keep away as the temperature of

the breaker is "HOT". High Temperature.

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Limit the time the breaker is

allowed to fire continuously. Clock and Thermometer.

4. BREAKER NOMENCLATURE 4.1 MAIN STRUCTURE CAL-225 thru CAL-3200

The hydraulic breaker consists of five main sections. This includes the Cylinder, Piston, Control Valve, Front Head and Head Cap.

1. The cylinder contains the piston and control valve.

2. Four through-bolts are assembled and hold the cylinder, head cap and front head together.

3. The piston strikes the chisel with a combination of oil

and gas pressure.

4. The control valve is located inside of the cylinder and is used to regulate the piston movement.

5. The chisel pin is located inside the front head and is

used to stop the chisel from coming out.

6. The head cap has pressurized nitrogen gas inside of it.

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CAL-4500 thru CAL-11000

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4-2. PRINCIPLES OF OPERATION

Elevating Strokes (Low Speed)

1. Operate the pedal and lever in the cab to supply the high-pressure oil into the hydraulic breaker. 2. The high-pressure oil enters the lower port D1 through passage D8 and forces the piston D2 to move up

and compress the nitrogen gas in chamber D4.

3. The high-pressure oil that flowed into passage D8 also makes to the control valve moves upward.

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Downward stroke

1. When the piston and control valve are in the upward position, port D1 is closed off and the high-pressure oil flow is re-routed though port D3. With the high-pressure oil flowing into the top side of the hydraulic breaker, combined with the compressed nitrogen in the head, the piston is forced downward against the chisel.

2. As the piston descends and strikes the chisel, the high-pressure in D6 becomes low-pressure while

passing through passage D7. The control valve goes down and returns to its original position with the aid of high-pressure oil in D5. High-pressure oil is re-directed back through port D1 and the cycle repeats itself.

5. REMOVAL & INSTALLATION OF THE HYDRAULIC BREAKER WARNING

• When attaching the hydraulic breaker, use an assistant that has been instructed by the host machine driver. All directions, signals etc. must be agreed to beforehand.

• The hydraulic breaker should only be attached to a host machine with sufficient load capacity. If the host

machine is too light, it may become unstable under load and tip over.

• Do not touch any parts when the boom is moving.

• Collect any oil that leaks out and dispose of it properly.

• Check the pressure relief valve on the hydraulic system.

• Check all hydraulic hose fittings and fasteners to ensure they are properly tightened.


• Never use your fingers to check for hole alignment. 5.1 REMOVAL OF THE HYDRAULIC BREAKER

1. Disconnect the hydraulic hoses connected to the stop valve on the carrier boom.

2. Cap off the hoses and the stop valve openings with the caps supplied in the toolbox.

3. Place blocks underneath to support the breaker off of the ground while not in use.

4. Remove the mounting pins that secure the breaker to the pivot linkages on the host machine.

5. Slowly move host machine away from disconnected breaker.

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5.2 STORING

1. Be sure to cap off the ends of the hoses on the disconnected breaker. 2. Avoid subjecting the breaker to the weather elements while not in use. Store inside or store outside on blocks with a suitable covering. 3. Grease the chisel thoroughly. 4. Follow these instructions to prevent the piston from rusting:

• Remove the chisel from the front cover.

• Remove the nitrogen gas from the head cap completely through the gas valve.

• Using a round pole and hammer, drive the piston up into the cylinder chamber. • Release any residual gas pressure out of the head cap. • Apply grease to the lower bearing in the front cover. Apply grease to the chisel, then re-attach to the

front cover.

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If the breaker is to be stored for long periods of time, it is recommended it be stored vertically. This will protect the internal seal components from being damaged due to the weight of the piston. Secure the hydraulic breaker during lengthy periods of non-use to ensure that it cannot fall over. 6. OPERATION Precautionary measures should be taken to rule out the risk of accident.

• Only operate the hydraulic breaker from the driver’s seat in the host machine.

• Close the front screen / splinter guard on the drivers cab to avoid injury from flying debris.

• Wear ear protection to prevent hearing impairment. Anyone in the immediate vicinity of breaker operations should also wear ear protection.

• Switch off the hydraulic breaker immediately if any one moves into the danger zone, that is within a

radius of at least 25 feet around the hydraulic hammer. Depending on the application greater distances may have to be observed.

6.1 PROPER OPERATION

Proper Downward Force

To break effectively, a proper download force has to be applied by the breaker. If the download force is insufficient, the breaking energy of the piston will not be sufficient for breaking rocks. The breaking force is then transferred to the breaker body, arm and boom of the base machine, resulting in possible damage to those components.

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Inversely, if the download force is excessive or the breaking is performed with the boom of the base machine raised, the machine may suddenly tilt forward when rocks are broken. The breaker body may violently hit against the rocks, resulting in machine damage.

Breaking under these conditions may also transmit shock loads to the carrier tracks, causing possible damage. Take the necessary precautions to avoid these situations. Always take care when applying a download force to the breaker. Do not break materials without the proper download force.

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Direction of Downward Force

Apply a download force in a perpendicular plane to the work piece. If the work piece is odd-shaped, the tool may slip during operation, causing the chisel and piston to break, or seize up. When breaking, select the point on the work piece that will allow the breaker to perform in a stable manner.

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6.2 OPERATION PRECAUTIONS

The operator should pay attention to the following points during operation.

• Stop the breaker operation immediately if the hydraulic hoses running to the breaker are observed to be vibrating excessively.

• Check to see if the high and low pressure hoses of the breaker vibrate excessively. If they do, the

accumulator may be defective. Contact your local Construction Attachments dealer in your territory for service information.

• Check for oil leakage at the hose fitting points. Retighten the fittings as necessary.

• Visually inspect the breaker chisel to determine if it has sufficient chisel stroke during operation.

(See below). If the chisel’s movement is restricted, the tool must be seized in the front head.

• Disassemble the front head, inspect the components and repair or replace any defective parts.

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Chisel Stroke

STOPPING

As soon as material is broken, stop the oil flow to the breaker. If the breaker is allowed run while under no load, it is considered to be “dry firing”. In this condition, the accumulator could be damaged, the bolts loosened or broken and the host machine could be affected adversely.

CAL-225 CAL-450 CAL-550 CAL-750 CAL-1000 CAL-1200STROKE (in) 1.28 1.61 1.89 1.50 1.70 1.77

CAL-2200 CAL-3200 CAL-4500 CAL-6000 CAL-8000 CAL-11000STROKE (in) 2.12 2.32 2.48 2.80 2.87 2.95

BREAKER MODEL

BREAKER MODEL

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DO NOT Use Breaker to Move Rocks.

As shown in the picture, do not use the breaker to move rocks. Damage to the breaker and the components on the host machine could occur.

DO NOT Use the Breaker as a Lever

Never use the hydraulic breaker as a crowbar, as this will cause the working tool to break.

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DO NOT Operate Breaker for Periods Longer than (1) Minute

In hard conditions, do not operate breaker for longer than (1) minute. Frequently move the chisel point to different points on the material being broken. Continuous breaking in one location raises the hydraulic oil temperature of the system to where internal components could be damaged. Also, the heat generated to the tip of the chisel could cause premature and excessive wear.

On a Hard, Large Rock, Start Breaking at the End Point

Beginning to break at a crack or at the end will enable even a big rock to be broken comparatively easily. Advancing in large steps will not improve working results. Advancing in small steps is more effective.

Operate the Breaker at a Proper Engine Speed

Break rocks at the specified engine speed. Raising the engine speed more than necessary does not increase the hammering force but raises the hydraulic oil temperature that could result in damage to the internal components of the breaker and host machine.

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DO NOT use Breaker in Water or Mud Without Prior Conversion

If water were to penetrate the percussion chamber, each blow would create a pressure wave. These pressure waves would cause irreparable damage to the stripper and seals on the hydraulic breaker. In addition, the piston would rust. Water could also penetrate the carrier’s hydraulic system. In order to avoid damage to the hydraulic breaker, a special kit is available for under water applications.

DO NOT Use the Breaker as a Sledgehammer

Before breaking material, always rest the breaker against the work piece. Never attempt to use the breaker and excavator boom as a sledgehammer to break material. This will cause extensive damage to the breaker and the host machine.

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DO NOT Operate the Host Machine with the Hydraulic Cylinders Fully Extended or Retracted

The host machine can be easily damaged when the breaker is operated with the cylinders positioned at the end of their stroke.

DO NOT Use the Breaker for Transport or Lift Purposes

The hydraulic breaker is not designed to lift or transport loads. The breaker may be damaged and the load being carried would be very unstable and dangerous.

Hydraulic Oil Warm-up Period Required

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If the breaker is operating in low ambient temperatures, the piston & seals could easily be damaged. Required warm-up time for the carrier engine is from five to twenty minutes. Actuate various hydraulic functions to ensure all hydraulic oil is circulated through system. Oil temperature must reach a minimum of 86o F.

6.3 LUBRICATION

Hydraulic breakers require proper viscosity of hydraulic oil & grease. Refer to the chart below when determining hydraulic oil requirements in extremely cold or hot weather conditions. Lubricate the contact faces in the front head between the working tool and the wear bushings.

Grease Gun Application

6.4 WORKING IN HIGH-TEMPERATURE CONDITIONS

The temperature of the hydraulic oil must be monitored to ensure it does not exceed 176o F. If higher temperatures are measured in the tank, an oil cooler must be fitted. Only use hydraulic oils of sufficient viscosity. In summer and tropical climates, the minimum requirement is a hydraulic oil type HLP 68.

6.5 WORKING IN LOW-TEMPERATURE CONDITIONS

When ambient temperatures don’t fall below -4o F, there are no special regulations, but the hydraulic oil must be warmed up before operating. This is achieved by

• Starting up the host machine motor. • Actuating the hydraulic circuits.

This raises the oil temperature. Once it has risen above 32o F, the hydraulic breaker can be operated. Leave the motor and the pumps of the host machine running during breaker operation.

Hydraulic Oil Grease

High Temperature Low Temperature

ISO VG 68 (61.2-74.8 cst)

ISO VG 46 (41.4-51.6 cst)

NLGI No.2 (265-295)

Model No. of Pumps

CAL-225 thru CAL-1200 5 - 6

CAL-2200 thru CAL-4500 7 - 8

CAL-6000 thru CAL-8000 10 - 11

CAL-11000 14 - 15

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Note The hydraulic breaker and host machine do not operate to full capacity until the oil temperature has reached at least 140o F. WARNING Feeding hydraulic oil into an extremely cold hydraulic breaker will cause internal stresses in the unit resulting in potential failure. If the breaker is used without preheating the hydraulic oil, the breaker seals may fracture and the diaphragm in the high-pressure accumulator may tear. Observe the host machines manufacturer’s regulations regarding operating conditions related to ambient temperature. 7. CHISEL (TOOL) WARNING: For safety reasons, the host machine must be switched off before performing the following service.

• DO NOT use your fingers to check whether the recesses on the working tool shaft are aligned to the slots for the chisel pin.

• Always wear protective glasses when fitting or removing the tool, since metal splinters may fly off when

hammering out the stopper pins.

• Clean away any dirt adhering to the working tool in the insert zone.

• Lubricate the contact faces in the front head between the working tool and the wear bushings.

• The chisel can only be installed in one position, with the recessed area on the tool aligned with the retaining pins in the front head.

7.1 REPLACEMENT OF THE CHISEL

1. CAL225 – CAL2200: Push the spring pin back into the hole. Push retaining pin out with a punch to release the tool.

2. CAL3200 – CAL11000: Knock out the stopper pin & rubber plug from the front head. Drive out the

retaining pins with a punch to release the tool.

3. Replace with a new chisel. Use reverse procedure for re-installing retaining pins. The chisel is heavy, so use extra caution when handling the tool.

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CAL225 - CAL2200

CAL3200 – CAL11000 7.2 ESSENTIAL POINTS IN USE Follow these guidelines to prevent damage to the chisel tool and lower bushing.

• Avoid improper lifting, twisting and hitting of the chisel tool. • Avoid allowing the breaker from getting wet due to outdoor storage. • Avoid injury from improper handling or installation of the tool chisel. • Avoid excessive heat to the chisel tool.

7.3 CHISEL SHAPES

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※Use only genuine Construction Attachments chisels for the hydraulic breaker. Substitute parts may not

meet the required design and safety specifications for this breaker and will void the warranty. 7.4 CAUSE OF TOOL DAMAGE

• Continuous side pressure due to leverage, incorrect driving angle or using the breaker to pull heavy objects.

• “Dry firing” which leads to damage on the chisel pin.

• Low temperatures that will cause the tool to be more susceptible to fatigue failure.

• Overheating of the tool by friction caused by improper lubrication and excessive bending.

• Excessive wear of the lower bushing allowing the piston to strike the top face of the chisel at an angle.

This will cause damage on the tool head as well as on the bottom of the piston.

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8. SERVICE 8.1 INSPECTION & MAINTENANCE

WARNING Use extreme care when disassembling the head cap: It could move suddenly due to the gas pressure in the head cap.

• Be sure to release the nitrogen gas out from the head cap completely before disassembly. • Be sure to completely tighten the through bolts with the specified torque before gas charging.

Use extreme care when disassembling the gas valve: It could be pressurized from the nitrogen gas in head cap. • If the nitrogen gas pressure isn’t released before the gas valve is disassembled, serious injury can result

from the gas valve being projected from the cylinder body due to the high gas pressure in the head cap. • Be sure to release the nitrogen gas completely out from the head cap before disassembling the gas valve.

• Use caution when pressurizing the head cap. Gas pressure may cause the chisel to move suddenly. • To avoid injury, DO NOT stand in front of the chisel while servicing breaker.

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• Discharge the gas pressure using the “L” wrench (5mm) (from gas valve kit) after removing the gas valve plug.

8.2 BOLTS During long periods of use, the tie rod bolts may loosen. Check tie rod bolts regularly. If the bolts require retightening, it is recommended they all be re-tightened together. In case of frequent loosening, consult your dealer. 8.3 GAS PRESSURE AND NITROGEN GAS CHARGING The hydraulic breaker operates with a combination of hydraulic oil & gas pressure. WARNING The head cap can only be filled with nitrogen. Filling with air or oxygen runs the RISK OF AN EXPLOSION!

• If the gas pressure in the head cap becomes higher than the recommended gas pressure, the breaker will get overloaded because the piston will have difficulty retracting into the head cap. If the gas pressure is lower than the recommended gas pressure, the breakers performance will become sluggish due to the gas pressure being unable to assist in the firing of the piston.

• The gas pressure requirement could change depending on the working conditions. Maintain the proper

gas pressure while operating the breaker.

• Check the head cap O-ring after charging the head cap to ensure it is maintaining the proper seal.

• If the working oil from the cylinder leaks into the head cap, replace the gas seals and piston O-rings. Check the cylinder bushings and piston for scratches.

• The pressure in head cap should be set according to the chart as follows.

NOTE: Gas pressure should only be

checked with the chisel protruding fully from the front cover.

Gas Pressure CAL225 – CAL4500 CAL6000 – CAL11000

Head Cap (㎏/㎠) 10 - 14 10 - 14

Accumulator (㎏/㎠) - 55 -60

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8.4 WEAR PARTS The following items are considered wear parts that will require replacement as needed.

• Chisel • Front Cover and Round Bushing • Chisel pins • Hydraulic Seals • Through Bolts • Hydraulic Hoses

SEALS: Replace hydraulic seals every (500) hours of actual operation or when kept over (6) months in storage. CHISEL PINS: When each chisel pin is excessively deformed, it is difficult to replace the chisel. Therefore,

every (100) to (150) hours of operation, change the face of each pin that comes in contact with the chisel. Both faces of each pin can be used.

Always use genuine Construction Attachments parts. Substitute parts may not meet the design criteria and may cause the breaker to be dangerous. Substitute parts will also void the breaker warranty. 8.5 FRONT COVER Limit the amount of wear between the chisel and front cover: When the clearance between the chisel and holder bushing becomes large, it is strongly recommended to replace these parts to prevent damage and reduced breaker performance. Exceeding the following wear allowances may damage

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other component parts, such as the piston and cylinder.

Model CAL225 – CAL750 CAL1000 – CAL3200 CAL4500 – CAL8000 CAL11000

mm 6 8 10 12 Wear Limit

Inch 0.230 0.315 0.394 0.472

8.6 WORKING PRESSURE The hydraulic breaker is designed to work in conjunction with the working hydraulic oil pressure supplied by the auxiliary hydraulic pump of the host machine. An additional relief valve on the incoming high-pressure line to the breaker is not required. If the oil pressure supplied by the host machine is greater than the breaker’s recommended oil pressure range, the breaker will produce a higher energy impact that may damage the breaker and host machine.

8.7 OIL TEMPERATURE The oil temperature is different according to working condition, but it is usually 122 - 176o F. If the breaker operates with oil temperatures over 176o F for extended periods of time, internal damage to the seals and accumulator (if equipped) will occur. Use caution to avoid oil temperature increases due to the following:

• Continuous breaking at the same point for over (1) minute intervals.

• Increasing engine speed does not necessarily increase the breaker’s blow rate. However, an increase an engine speed will cause additional hydraulic oil to be forced over the relief valve. This condition will cause an oil temperature increase. Set engine throttle at the position that will deliver the recommended amount of hydraulic oil to the breaker.

• Keep all hydraulic oil cooling elements clean and in proper working condition.

8.8 ACCUMULATOR (CAL4500 – CAL11000)

CAL-225 thru CAL-1200 CAL-2200 thru CAL-11000

Kg/cm 175 210

PSI 2,500 3,000

BREAKER MODELSRELIEF VALVE SETTING

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Replace the accumulator if the high-pressure line vibrates erratically. When replacing the accumulator, replace the O-ring and back up ring at the same time. Inspect the exhaust port under the accumulator for scratches. If scratches are present, clean the inside of breaker. After replacement and inspection, torque the socket bolts that secure the accumulator to the proper values. 8.9 OIL LEAKAGE Check for oil leakage at all connections. A little oil leakage between the chisel and front cover is acceptable as it helps lubricate the chisel. If excessive oil leakage is observed, check and replace the seals. When installing seals, apply hydraulic oil to the seal kit and the seal grooves. Check the Following When Replacing Seals.

• Inspect seals for any physical damage. Make sure seals are properly seated after installation.

• Only service the breaker in a clean working environment.

• If a seal gets damaged during installation, remove and replace it with a good seal. Do not place the breaker back into service with a defective seal.

• When seals get damaged, they become ineffective in their ability to prevent oil leakage. If seals are

replaced and the breaker still leaks oil, consult your local Construction Attachments dealer. 8.10 CONTAMINATION OF WORKING OIL Contaminated hydraulic oil will cause damage to the control valve and reduce the performance of the breaker. Contaminated oil will also damage the internal components to the host machine’s hydraulic pumps. Keep the hydraulic oil clean. Replace the hydraulic filter on the host machine every (100) hours and the hydraulic oil every (600) hours. When installing the breaker on older host machines, it is highly recommended to replace the hydraulic oil and filter prior to placing the breaker into service. 8.11 CHARGING THE GAS IN THE HEAD CAP

1. Remove the chisel from the front cover. 2. Connect hose (8) to the gas bottle (10).

3. Remove the plug (3) from the gas valve (2) on head cap using the "L" wrench (5mm).

4. Connect the gas-charging valve (4) to the gas valve (2).

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5. Be sure to tighten the release valve (7) of the gas-charging valve (4).

6. Slowly open the valve (9) of gas bottle (10). Note that a high volume of gas entering the head cap quickly could damage the pressure gauge. Open gas bottle slowly.

7. When the pressure gauge (5) shows 10% above the desired pressure, close the valve (9) on the gas bottle

(10).

8. Allow the breaker to sit for (5) minutes. This will allow the nitrogen to stabilize in the head cap. Re-check the pressure on the pressure gauge (5) while keeping the button (6) of gas charging- valve pushed down.

9. If the pressure is lower than desired, add more gas. If the pressure is higher than desired, open the release

(7) valve slowly and release the gas until the desired pressure is achieved. Be sure to keep the button (6) of gas charging-valve pushed down.

10. Open the release valve (7) only to release any remaining gas in the gas charging-valve after pulling the

button (6) of gas-charging valve (4) up. 11. Disconnect gas-charging valve (4) from the gas valve (2) of the head cap.

12. Install the plug (3) to gas valve (2). Check for leakage around the gas valve (2).

After use, replace the cap on the gas bottle to avoid damage to the valve on the gas bottle. Check to ensure the gas valve is properly attached to the gas bottle. Do not expose the gas bottle to direct sunlight for extended periods of time.

8.12 CHARGING THE GAS IN THE ACCUMULATOR

1. Connect hose (8) to the gas bottle (10). 2. Remove the plug (3) from the gas valve (2) with "L" wrench (5mm).

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3. Connect gas-charging valve (4) to the accumulator gas valve (1).

4. Open the adjuster (2) on the accumulator cover (1).


6. Open the valve (9) of gas bottle (10) slowly. Note that a high volume of gas entering the accumulator quickly could damage the pressure gauge. Open gas bottle slowly.

7. When the pressure gauge (5) shows 10% above the desired pressure, close the valve (9) on the gas bottle

(10).

8. Allow the breaker to sit for (5) minutes. This will allow the nitrogen to stabilize in the head cap. Re-check the pressure on the pressure gauge (5) while keeping the button (6) of gas charging- valve pushed down.

9. If the pressure is lower than desired, add more gas. If the pressure is higher than desired, open the release

(7) valve slowly and release the gas until the desired pressure is achieved. Be sure to keep the button (6) of gas charging-valve pushed down.

10. Lock the adjuster (2) to the accumulator cover (1).

11. Open the release valve (7) only to release any remaining gas in the gas charging-valve after pulling the

button (6) of gas-charging valve (4) up.

12. Disconnect the gas-charging valve (4) from the gas valve of the accumulator cover (1).

13. Install the plug (3) to the gas valve in the accumulator cover (1). Check for leakage around the gas valve (2).

After use, replace the cap on the gas bottle to avoid damage to the valve on the gas bottle. Check to ensure the gas valve is properly attached to the gas bottle. Do not expose the gas bottle to direct sunlight for extended periods of time.

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8.13 CHECKING THE GAS PRESSURE IN THE HEAD CAP Before checking head cap pressure, note if the breaker’s impact power is low or irregular. Also note whether the breaker has been operated at a high oil temperature. 1. Remove the plug (3) out of the gas valve (2) on the head cap using the "L" wrench (5mm). 2. Connect gas-charging valve (4) to the gas valve (2).


4. Check the pressure on pressure gauge (5) while keeping the button (6) of gas-charging valve pushed down.

5. If the gas pressure is lower than desired, pull the button (6) up. Open the release valve (7) to release any

remaining gas in the gas charging-valve (4). Re-tighten release valve (7). Use procedure from Section 8.11 for proper filling instructions.

6. If the gas pressure is higher than desired, slowly open the release valve (7) with the button (6) of the gas-

charging valve depressed until the gas pressure is reduced to the desired pressure.

7. With the gas pressure adjusted, pull the button (6) of gas-charging valve (4) up. Slowly open the release valve (7) to remove any gas from the gas-charging valve.

8. Disconnect the gas-charging valve (4) from the gas valve (2) in the head cap.

9. Install the plug (3) in to the gas valve (2). Check for gas leakage around the gas valve (2).

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8.14 CHECKING THE GAS PRESSURE IN THE ACCUMULATOR

1. Check the high-pressure line attached to the breaker to determine if the line vibrates erratically. 2. Remove the plug (3) out of gas valve (2) on head cap using the "L" wrench (5mm).

3. Connect the gas-charging valve (4) to the valve of Accumulator cover (1).


5. Open the adjuster (2) on the accumulator cover (1).

6. Check the pressure on the pressure gauge (5) while keeping the button (6) pushed down.

7. If the gas pressure is lower than desired, pull the button (6) up. Open the release valve (7) to release any

remaining gas in the gas charging-valve (4). Re-tighten release valve (7). Use procedure from Section 8.12 for proper filling instructions.

8. If the gas pressure is higher than desired, slowly open the release valve (7) with the button (6) of the gas-

charging valve depressed until the gas pressure is reduced to the desired pressure.

9. With the gas pressure adjusted, pull the button (6) of gas-charging valve (4) up. Slowly open the release valve (7) to remove any gas from the gas-charging valve

10. Lock the adjuster (2) to the accumulator cover (1).

11. Disconnect the gas-charging valve (4) from the gas valve (2) in the accumulator cover (1).

12. Install the plug (3) in to the gas valve (1). Check for gas leakage around the accumulator cover (1).

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9. INSTALLATION OF THE HYDRAULIC BREAKER 9.1 GENERAL VIEW OF BREAKER INSTALLED TO BASE MACHINE

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The hydraulic breaker is not self-powered. It makes use of hydraulic power systems of the host machines it is mounted on, such as excavators, mini-excavators, backhoe loaders, skid steers etc. To enable host machines to operate with these attachments, the hydraulic power system has to be converted accordingly. Hydraulic breakers require a proper oil flow and pump pressure. Breakers have a required pressure relief setting needed to operate properly and ensure the host machine’s hydraulic components are not damaged. The chart below shows the required pressure relief setting that is 10kg/cm2 less than the host machine’s main relief pressure.

• CAL225 – CAL1200: 2,500 psi (175 kg/cm2)

• CAL2200 – CAL11000: 3,000 psi (210 kg/cm2) 9.2 INSTALLATION PRECAUTIONS When the bucket and breaker operation are performed alternately, the hydraulic breaker is connected to the host machine with the two mounting pins, allowing the bucket and breaker to be easily interchanged with each other. However, as the hydraulic circuit is easily apt to be damaged by contamination, remove and install the breaker in the following procedures with care. 1. Select a level work site that is free from mud, dust and other contaminants. 2. Move the host machine into position. Stop the engine and turn off the key. The hydraulic tank on the host

machine may be pressurized. Bleed any pressurized air from the oil tank. With the host machine positioned as shown in the picture; the breaker and bucket are positioned for easy replacement.

CAUTION The stop valve must be closed before the breaker can be removed from the excavator.

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9.3 HYDRAULIC SYSTEM

9.4 PROPER INPUT OIL FLOW To energize the breaker will require either a flow divider valve or a flow control valve in order to control the output oil flow from the host machine’s hydraulic pump. High-pressure flow from the host machine determines the blow rate of the breaker. The valve setup also reduces the peak pressure subjected to the breaker.

• Pressure Pulse

The average operating pressure of the pump at the breaker input line must be much less than that of the compensating pressure. This prevents abrasion of the regulator and swash plate supporter of pump.

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• Outlet Pressure Pulse of Pump (Pmin. to Pmax.)

Pressure displacement must be within 1,160 psi (82 kg/cm2) in 1 cycle of blow except for instantaneous peak pressure within 10 milliseconds, in order to protect the pump.

• Outlet Pressure Pulse of Pump (Pmin)

An instantaneous peak pressure drop in the negative direction must be within 580 psi (41 kg/cm2), when measured at the supply line. This is to ensure long pump life.

Pressure Pulse (Pmin, Pump & Pmin, Breaker)

When operating the breaker, the minimum peak pressure of the pump outlet must be higher than that the breaker inlet. (Pmin, Pump ≥Pmin, Breaker). This is to check the load on the control valve and protect the valves.

• Inlet Pressure Pulse of Breaker (Pmin, Breaker)

When operating the breaker, the minimum value of peak pressure of the inlet must be kept higher than the diaphragm recharge pressure of approximately 870 psi (61 kg/cm2). (Pmin, Breaker ≥ 870 psi (61 kg/cm2)). This is to protect hydraulic components and achieve diaphragm efficiency.

9.5 ADJUSTING IMPACT BLOW RATE

The blow rate of the breaker is adjusted by changing the oil flow rate from the host machine. This is accomplished by reducing the pressure in the control valve at the breaker line. For more blows, set the reducing pressure at a lower rate. For fewer blows, set the reducing pressure higher.

(CAL750 – CAL3200) (CAL4500 – CAL11000)

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The blow rate of the breaker can be adjusted by doing the following procedure.

1. Release the adjuster nut 2. High speed (Low power): turn adjuster to counter-clockwise. 3. Low speed (High power): turn adjuster to clockwise 4. Tighten the adjuster nut after setting.

CAUTION The maximum adjustment to the blow rate is accomplished in (1) counter clockwise rotation. DO NOT adjust the blow adjuster past (1) rotation. One eighth of a turn to the blow adjuster will change the blow rate by 10-15 bpm. Use caution so that the blow rate matches the work being done. 9.6 HYDRAULIC PIPE LINES AND CONTROLS 1. The following hydraulic components of the host machine are used during the operation of the breaker.

• Hydraulic oil tank. • Oil pump • Auxiliary Hydraulic Control Valve

2. The following hydraulic components have to be installed in order to complete the circuit to the breaker.

• Hydraulic control valve (when a spare valve is not available in control valve bank of a host machine.) • Control pedal or lever (for breaker control) • High pressure pipe lines (for supply of high pressure oil to breaker) • Low pressure pipe lines (for return of low pressure oil to hydraulic oil tank) • Stop valve (For shutting off oil lines when the breaker is replaced with bucket etc.)

CAUTION

• If excavator has a suitable hydraulic system, check the width of the hydraulic lines to determine flow capacity.

• Check the connections on the hydraulic breaker and the breaker hoses.

• The connecting threads must be undamaged and free of sand or similar foreign bodies.

• Check to be sure the pressure relief valve on the hydraulic system has been approved by the host machine

manufacturer.

• Ensure that the pressure relief valve has been set correctly, i.e. to the maximum permissible operating pressure of the hydraulic breaker. (Operating pressure + 435 psi (30.6 kg/cm2) min)

• DO NOT run any hydraulic lines through the driver’s cab.

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• As the hydraulic circuit varies with the host machine, hydraulic pressure, oil capacity, pressure loss, etc.

of the host machine must be verified before the breaker is placed into service. Do not guess or assume written specifications are accurate. Use as flow meter and hydraulic pressure gauge.

• As the hydraulic pipe lines (hoses, pipes and fittings) are made of materials carefully selected in

consideration of durability, use only genuine replacement parts. 10. DISASSEMBLY & REASSEMBLY WARNING If there is any nitrogen gas in the hydraulic breaker, it could be very dangerous. Be sure the gas pressure in the head cap and accumulator has been released before doing any service work on the breaker. 10.1 DISASSEMBLING

1. Support the breaker on wooden supports of the appropriate size. 2. Relieve the nitrogen gas in head cap and accumulator (if equipped).

3. Remove nuts of main body through bolts.

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4. Disassemble the head cap with a hoist or chain block.

5. Disassemble the cylinder body from the front cover using the eyebolt provided along with a hoist or chain

block. Slide cylinder body in the direction indicated by the arrow in the picture below.

6. Position the cylinder body in a vertical position. Attach the eyebolt to the piston and remove the piston from

the cylinder body using a hoist or chain block as shown in the picture below. 7. Remove the through bolts from the front cover with a stander spanner.

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(CAL-225 – CAL2200)

(CAL3200 – CAL11000)

8. Remove seals & o-rings

Using a screw driver, carefully remove the dust seal, u-packing, buffer ring, step seal, and gas seal from the lower area of the cylinder and cylinder bushing.

WARNING Excessive kinking of seals and o-rings will cause cracks and subsequent hydraulic failure. CAUTION

• Once seals and O-rings are removed, they should not be used again.

• Use only new and genuine Construction Attachment replacement parts.

• Make sure all seals are properly orientated before seating them into piston groove. Seals installed improperly will leak.

• Lightly coat seals and o-rings with oil before installation.

MODEL CYLINDER CYLINDER BUSH DESCRIPTION

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CAL-225

CAL-450

CAL-550

CAL-750

CAL-1000

CAL-1200

CAL-2200

CAL-3200

CAL-4500

CAL-6000

CAL-8000

CAL-11000

① Dust Seal

② U-Packing

③ Buffer Ring Set (Buffer Ring + Back Up Ring or Step Seal)

④ Step Seal

⑤ Gas Ring Set (Gas Ring +Back Up Ring)

The part numbers & shape of seals & o-rings differ from each model. Refer to part lists for specific seal kit information. 10.2 INSPECTION 1. Seals While seals are still in there original position, check for scratches and deformation. Do not remove to check.

Even a small scratch will lead to oil leakage.

Damaged Seals

Replace the hydraulic seals every (500) hours of actual operation or when kept over (6) months in storage. 2. Control Valve

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Inspect the valve for signs of seizure or scuffing. If marks left by the seizure are even small, polish them out

by using the fine oilstone or sand paper (#1000~1200). The corresponding marks on the valve bushing or valve cap should be removed in the same manner.

If seizures or scratches are excessive, replace immediately with a new control valve assembly. 3. Piston Periodically the lower end of piston must be checked for deformation.

Check piston for seizure marks and scuffing. If such marks appear on the surface, remove by polishing with an

oilstone or sand paper (#1000~1200). Corresponding marks on the mating parts should also be treated in the same manner.

10.3 ASSEMBLING 1. Assemble the Seals. Once the cylinder bushing and cylinder bore

have been thoroughly cleaned, lightly coat sealing elements with hydraulic oil before assembling.

2. Assembly of the Lower Bushing and Front Cover.

1. Knock out the rubber plugs and stopper pins using a hammer and punch.

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2. Disassemble the worn front cover and lower bushing. There are several methods to effectively remove lower bushing.

WARNING: Wear Safety Approved Eye Protection. A. Remove the bushings using oxy-arc cutting. This requires a skilled worker. DO NOT allow the front

head from being overheated.

B. Press out the bushings with the appropriately sized pin as shown in the picture below.

This work can only be performed in a well-equipped workshop with a hydraulic press rated at 200 tons or more capacity.

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C. If no oxy-arc cutting & press are available to remove the bushings, the following procedure is possible.

• Apply thick axial or radial welding beads inside the worn lower bushing using an electrode welder.

• Upon cooling the lower bushing will contract and loosen in it’s seat.

3. Before fitting the round bushing into the front cover, heat the bore area in the front cover to make the bore expand. Freeze the bushings in liquid nitrogen (N2) to make then shrink and be undersized for assembly.

CAUTION Do not allow overheating of the front cover bore area. It can become weak.

4. Keep the contact surfaces clean during assembly. Press bushing evenly into front cover bore. Check to be sure bushing is fully seated into bore.

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5. Install the stopper pins & rubber plugs.

6. General assembly

A. Attach the through-bolts to the front cover.

B. Replace the seals in the cylinder seal and lower bushing area.

C. Slide the piston into cylinder body after lubricating the piston and cylinder thoroughly.

D. Slide the cylinder bushing onto the piston as shown picture using a rubber hammer.

CAL-225 thru CAL-2200 CAL-3200 thru CAL-11000

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E. Apply approximately 150-250 cc of hydraulic oil to the inside of the head cap.

F. Connect the cylinder body, front cover and head cap together with through-bolts. Tighten the nuts on the

through-bolts to their specified torque.

G. Fill the cylinder body with hydraulic oil through the ports on the cylinder body.

H. Tighten the hose adapters to the inlet and exhaust ports on the cylinder body.

I. Install and tighten the gas valve to its specified torque.

J. Pressurize the head cap with nitrogen gas.

K. Install the bulkhead cap to complete assembly.

8. Disassembling bracket (Box Type)

A. Remove the upper urethane from the cylinder body after the bulk cap has been removed.

B. Take the main body out from the bracket using a crane or hoist.

C. To re-assemble bracket, perform the above procedure in the reverse manner.

D. 9. Chisel Replacement

CAL225 – CAL 2200: Push the spring pin back into the hole in the cylinder body. Using a punch, push out

the retaining pin to release the chisel.

CAL3200 – CAL11000: Knock the stopper pins & rubber plugs out of the cylinder body. Using a hammer and punch, drive the retaining pins out to release the chisel.

Replace the new chisel after removed.

NOTE: The chisel is heavy. Use caution when installing or removing chisel.

10. Breaker lifting point

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11. Suitable Eyebolt Size for Breaker Main Body

10.4 REPAIRING PARTS When correcting imperfections on sliding surfaces, finish surfaces as smooth as possible. Use an oilstone, emery paper or flex hone. Keep in mind that overworking may cause parts to malfunction. Tool for correction

Grain size or Type Name of Tool

Rough Finish Finish Operating Method

Model Weight

(lbs) Eye Bolt Allowed Weight (lbs)

CAL-225 121 M10 330

CAL-450 143 M10 330

CAL-550 257 M10 330

CAL-750 334 M12 484

CAL-1000 572 M16 990

CAL-1200 572 M16 990

CAL-2200 999 M20 1,386

CAL-3200 1,379 M24 2,090

CAL-4500 1,929 M24 2,090

CAL-6000 2,640 M30 3,300

CAL-8000 2,860 M30 3,300

CAL-11000 3,520 M36 5,060

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Oilstone Rough and medium grain Fine Grain

Emery Paper #100, #160, #240 #400, #600 Polish perpendicular to a sliding direction.

1. Cylinder bushing When using a buffing grindstone, move the grinder in the correct direction relative to the circumference. If the grinder is led straight ahead, circularity of the bore will be ruined. Wash the parts thoroughly after grinding operation.

2. Cylinder Imperfections on the sliding surface may cause malfunction or oil leakage of the cylinder. Correct imperfections to machined parts at an early stage, using an oilstone and emery paper.

CAUTION ON USING A BUFFER GRINDER

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Kind of Fault Condition Remedy

Vertical Scratch

A striped fault running in the sliding direction of the blow piston.

If burrs stick out above labyrinth grooves, remove burrs and correct vertical faults with oil stone and/ or emery paper.

Galling

A localized fault that is wider than the vertical scratch and is caused by sliding motion.

Finish galling with an oil stone until no step exists on the outer surface and then finish with fine emery paper.

Chipping

Corner of sliding section is chipped.

Finish an edge produced by chipping smoothly with an oilstone.

Vermin

A vermin-like fault caused by cavitations located at the corner of a sliding part.

A vermin causes galling if left uncorrected. Remove it with an air grinder and finish it smoothly with an oilstone.

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3. Piston Correct faults at an early stage, using an oilstone and emery paper.

CAUTION ON USING A BUFFER GRINDER

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Kind of Fault Condition Remedy

Vertical Scratch

Striped scratches caused by sliding motion.

Remove burrs on the surface by polishing in the circumferential direction.

Scratch in labyrinth grooves

Correct scratches at an early stage as scratches in this area may develop into a fatal failure of the cylinder.

Removes burrs sticking above labyrinth grooves and finish edges to remedy vertical scratches.

Reparation of vertical scratch and/ or rust pit

Repair piston surface on a polishing machine. Remove burrs on surface by polishing in a circumferential direction for a maximum 0.002” less than the nominal diameter. If scratches and/or rust pitting still remain, replace piston with a new one.

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4. Damage on the impact surface Damage to the impact surface on a piston will have an adverse effect on the chisel. Correct it at an early stage or replace the piston with a new one. 1. Collapse: If the impact surface has a collapsed area of .08” or over in depth, replace the piston with a new one. If the impact surface has a step of less than .04” in depth, smooth the area. 2. Chipping and Peeling-off If the impact surface shows a localized chipping or peeling-off area, correct the area to prevent the deformation from progressing.

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3. Chipping-off at edge of impact surface. Replace piston with a new one.

11. MAINTENANCE PERFORMED BY THE OPERATOR DAILY MAINTENANCE

• Tighten loose connections. • Grease chisel shank and chisel bushings. • Observe oil temperature, all lines and connections, as well as impact efficiency and smoothness of

operation. WEEKLY MAINTENANCE

• Remove retaining pin(s) and check condition. • Remove chisel and check chisel shank for wear. • Remove burrs from retaining pin groove of the chisel. • Check that the chisel has received sufficient greasing.

MONTHLY MAINTENANCE

• Check chisel bushings for wear. • Check condition of vibration dampening mechanism. • Check condition of other wear parts and hoses.

WHEN CHANGING CHISEL OR APPROXIMATELY (4) TIMES PER YEAR

• Check wear to working chisel. • Check wear to lower wear bushings. • Check adapter and breaker bracket for cracks. • Check impact face of piston for wear or damage. • Check impact face of working chisel for damage. • Check retainer bars for burring.

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• Check chisel for burring. AS REQUIRED

• Replace bent and squashed pipes. • Replace damaged hoses. • Check pressure in head cap and accumulator. • Check adapter bolts for wear.

12. TROUBLE SHOOTING 12.1 MALFUNCTIONS Prerequisites for the normal operation and long life of the Construction Attachment Hydraulic Breaker:

• Supply of accurate rates (Pressure ‘P’ and flow rate ‘Q’) to hydraulic breaker of this series. • Use of clean hydraulic oil. • Proper operation as described in the operators manual.

If the hydraulic breaker is not working correctly, check the hydraulic system of the host machine thoroughly before making any repairs to the breaker. Hydraulic breaker problems can be affected by a hydraulic system that is not operating to specifications or such problems as a plugged oil filter or hydraulic filter in the host machine. Connect a flow meter to the host machine to check the hydraulic pump output, relief valve setting and tube lines to check flow and pressure.

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The following trouble shooting guide has been prepared to address common issues relating to the operation and performance of the hydraulic breaker.

Conditions Causes Countermeasures

Breaker does not work Low pressure relief valve setting. Check and adjust pressure on relief valve setting.

High pressure relief valve setting. Check and adjust pressure on relief valve setting. Breaker easily damaged due to

too strong impact power. Gas pressure is too high. Check the gas pressure. Poor heat radiation of base machine.

Have excavator manufacturer check.

Premature wear of pump. Have excavator manufacturer check.

Rapid increase in oil temperature

Clogged piping. Required flushing.

Hose pulsation on the return side The amount of oil flow is too low. Check oil flow.

Hose pulsation on the high-pressure line Gas pressure is too low or high Check the gas pressure.

Emulsification of hydraulic oil Entering of water into oil. Immediately replace hydraulic oil.

Insufficient output of engine. Decrease the gas pressure and increase RPM.

Drop of engine performance. Have excavator manufacturer check.

Excessive decrease in engine RPM

Excessively low temperature of oil. Required warming-up.

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Conditions Causes Countermeasure

Insufficient power (PｘQ) Check power. Insufficient down pressure on chisel. Proper instructions.

Clogged piping. Check and repair (Flushing).

Seizure of breaker. Repair or replace worm parts.

Filling up of hydraulic oil in head cap.

Replace gas seal and check the piston.

Breaker will not work.

Lack of hydraulic oil. Refill oil.

Insufficient power (PｘQ) Check power.

Clogged piping. Check and repair (Flushing).

Gas pressure is too high. Check gas pressure.

Damaged seals. Replace seals.

Stop hammering or erratic action in approx. 30~90min. operation

Filling up of hydraulic oil in head cap.

Replace gas seal and check the piston.

Use of hammering chisel in bent condition. Apply down force in tool direction.

Breakage of chisel Use of chisel as lever, move rocks with chisel.

Check if any excessive play on arms, link & pins.

Melting of chisel point Long time continuous hammering in one place. Relocate.

Cracking of chisel point Full power operation from the outset.

Low speed operation for first 30 minutes.

Difficulty in attach and removing chisel point Deformation of chisel pin. Regular check & grinding needed.

Excessively worn urethane (Box type). Replace. Excessive play between bracket

and breaker body Loosened side bolts (Side type). Retighten bolts.

Premature wear of front cover Lack of grease. Proper instruction.

Insufficient power (PｘQ) Check power.

Insufficient down pressure on chisel. Proper instructions. Low number of blows


Gas pressure is too low. Recharge the N2 gas. Insufficient down pressure on chisel. Proper instructions.

Weak impact force

Insufficient power (PｘQ) Proper instructions.

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Breakage of chisel in front cover. Replace tool and check the piston.

12.2 OIL LEAKAGE Even if oil leaks, there may not be cause for maintenance. Check the following points listed below. The operator can check for possible remedies before contacting dealer.

Area of Oil Leakage Conditions Causes & Remedies

Between the chisel and front cover A large amount of oil is leaking. Seals are damaged. Replace.

Upper part Oil leaking from hose adapter portion.

Loose breaker hoses and adapter. Replace.

Oil leakage from reassembly of Valve after overhaul.

Check that O-ring is damaged. Replace.

Oil leakage Loosened through-bolts & nuts. Retighten. Between the cylinder & head cap

Oil leakage (also gas leakage)

Check that gas seal and O-ring are damaged and oil & piston condition. Replace.

Between cylinder & front head Oil leakage Check that seals of cylinder are damaged. Replace.

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12.3 POOR OPERATION OF BREAKER

Conditions Major causes Remedies

Oil temperature is too low.

Required warming up the engine of base machine from five to twenty minutes and moving the boom. Oil temperature must reach to min. 86o F.

Main control valve (Excavator) does not operate properly.

Check conditions of main control valve.

N2 gas pressure is too high in head cap and setting pressure of relief valve is low.

Check gas pressure and relief valve.

Does not impact

Poor performance of hydraulic pump. (Excavator)

Contact excavator manufacturer immediately.

Oil temperature increased due to lack of hydraulic oil. Supplement of hydraulic oil.

Gas pressure in head cap is too high. Check gas pressure.

Relief valve is set too low. Check pressure of relief valve.

Not enough down pressure on chisel.

Apply enough down pressure with arm or boom of base machine.

The clearance between the chisel and front cover are too large.

Check the clearance between chisel and front cover.

Wear on top of chisel. Disassemble chisel to check.

Poor performance of hydraulic pump and backpressure are too high.


Foreign material inside main valve. Disassemble and clean.

Irregular blows it operates normally at the beginning.

Seizure of piston & cylinder. Overhaul and check.

Low gas pressure in back head. Check gas pressure.


Lack of impact

Not enough down pressure on chisel.

Apply enough down pressure with arm and boom.

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Setting pressure of relief valve is too low. Check pressure of relief valve.

Poor performance of hydraulic pump.


Operating pressure is too high. Check setting pressure or gas pressure.

13. TORQUE Before starting work, check all the bolts for proper tightness. Retighten loose bolts to the specified torque referred to in the manual. The tightening torque of each bolt is as follows.

13.1 THROUGH BOLTS

FEATURE CAL-225 CAL-450 CAL-550 CAL-750 CAL-1000 CAL-1200

TORQUE (ft-lbs) 326 326 326 362 724 724

TORQUE (kg-m) 45 45 45 50 100 100


TORQUE (ft-lbs) 941 1,085 1,809 2,315 2,605 2,605

TORQUE (kg-m) 130 150 250 320 360 360

BREAKER MODELS

BREAKER MODELS

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13.2 BULK CAP BOLTS

*CAL-4500 EXTERNAL VALVE CASE BOLT 125 Kg-m (904 ft-lbs) 13.3 ACCUMULATOR BODY BOLTS


TORQUE (ft-lbs) 31 31 80 80 152 152

TORQUE (kg-m) 4.3 4.3 11 11 21 21


TORQUE (ft-lbs) 210 391 528 926 926 1,201

TORQUE (kg-m) 29 54 73 128 128 166

BREAKER MODELS

BREAKER MODELS

FEATURE CAL-6000 CAL-8000 CAL-11000

TORQUE (ft-lbs) 1,281 1,281 1,281

TORQUE (kg-m) 177 177 177

BREAKER MODELS

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13.4 ACCUMULATOR COVER BOLTS

13.5 SPANNER SIZE (mm) FOR BOLTS OF HYDRAULIC BREAKERS

MODELS THROUGH BOLTS BULK CAPS SIDE BOLTS ACC’ BODIES ACC’ COVERS

CAL-225 27 19 27

CAL-450 27 19 27

CAL-550 36 24 32

CAL-750 36 24 32

CAL-1000 46 30 41

CAL-1200 46 30 41

CAL-2200 50 32 46

CAL-3200 60 41 60

CAL-4500 65 46 65

CAL-6000 70 55 70 22(L) 17(L)

CAL-8000 80 55 70 22(L) 17(L)

CAL-11000 90 56 NON 22(L) 17(L)

Remark; “L” → L Wrench

FEATURE CAL-6000 CAL-8000 CAL-11000

TORQUE (ft-lbs) 333 333 333

TORQUE (kg-m) 46 46 46

BREAKER MODELS

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14. SERVICE WARRANTY REGISTRATION & WARRANTY CLAIMS FILING OF WARRANTY REGISTRATION CARD ☞ Warranty registration card must be completed by dealer at the time of product delivery to the end user. ☞ Copy A from warranty registration card must be returned to Construction Attachments within (15) days after

the installation inspection is carried out and the card is filled out with the corresponding information . ☞ If the excavator is replaced during warranty time with another, the installation to the excavator must be

inspected and approved and corresponding information must be sent to Construction Attachments. ☞ No warranty claims will be handled before the warranty registration card is received by Construction Attachments. ☞ Distribution 1st copy A Construction Attachments 2nd copy B Dealer 3rd copy C Customer NOTE: You will receive prompter service after completing and returning your registration card.

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WWAARRRRAANNTTYY RREEGGIISSTTRRAATTIIOONN CCAARRDD

MODEL SERIAL NUMBER GAS PRESSURE (HEAD CAP)

GAS PRESSURE (ACCUMULATOR)

KG/CM2 KG/CM2

1. CUSTOMER AND DATES RELATED

CUSTOMER NAME CUSTOMER ADDRESS

DISTRIBUTOR NAME LOCATION OF DELIVERY

DATE OF DELIVERY / /

DATE OF INSPECTION / /

2. ACCESSORIES

NO ACCESSORIES NO ACCESSORIES

1 BREAKER TOOL YES□, NO□ 5 MAINTENANCE TOOLS YES□, NO□

2 GAS CHARGING KIT YES□, NO□ 6 TOOL BOX YES□, NO□

3 GAS BOTTLE YES□, NO□ 7 OPERATION MANUAL YES□, NO□

4 SPRING GUARD HOSE YES□, NO□

3. TYPE AND CONDITION OF BASE CARRIER

MAKER MODEL M.F.GYEAR / /

TOTAL WEIGHT TON

MAX. OUTPUT OF PUMPS SUPPLYING L/MIN

OPERATING PRESSURE KG/CM2 OPERATING OIL FLOW L/MIN

MAIN RELIEF SET PRESSURE

KG/CM2 2ND RELIEF SET PRESSURE KG/CM2

OIL COOLER YES□ NO□ OIL FILTER YES□ NO□

4. WARRANTY

DATE OF START / /

DATE OF EXPIRY / /

HOURS OF EXPIRY REMARKS

5. ACKNOWLEDGEMENT & COMMENT

SIGNATURE INSPECTOR’S COMMENT / DISTRIBUTOR

NAME DATE:

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INSPECTOR’S COMMENT / CUSTOMER I hereby acknowledge that the product has been delivered in satisfactory condition and operates satisfactorily, and that I received all items as checked above, and that all aspect of the standard warranty and suggestions in use has been fully explained to me.

SIGNATURE

SSEERRVVIICCEE RREEPPOORRTT

1. CUSTOMER AND DATES RELATED

CUSTOMER NAME CUSTOMER ADDRESS

DISTRIBUTOR NAME DELIVERY DATE TO DISRRIBUTOR

/ / 200

LOCATION OF PRODUCT

DATE OF FAILURE

/ / 200

DATE OF REPAIR (SERVICE)

/ / 200

PERIOD OF WARRANTY

/ / 200 ~ / / 200

2. TYPE AND CONDITION OF BASE CARRIER

MAKER MODEL MFG. YEAR

/ /

MAX. OUTPUT OF PUMPS SUPPLYING

L/MIN

3. TYPE AND CONDITION OF PRODUCT

OPERATING HOURS OPERATING PRESSURE

KG/CM2

B/H GAS PRESSURE

KG/CM2

MODEL & SERIAL NO.

CAL

(S/N; ) OIL FLOW

L/MIN

2ND RELIEF SET PRESSURE

KG/CM2

ACC’ GAS PRESSURE

KG/CM2

4. FAILURE INFORMATION

OUTLINE :

CAUSE :

STEP & RESULT

DETAILED REPORT □ ATTACHED

PHOTOS □ ATTACHED

5. WARRANTY CLAIM PARTS

PART NAME PART NO Q’TY PART NAME PART NO Q’TY

6. DECISION & COMMENT

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DISTRIBUTOR (OR SERVICE MAN) COMMENT

DATE OF CLAIM SIGNATURE

15. WARRANTY POLICY Construction Attachments Inc. provides the following warranty: THE WARRANTY PERIOD The warranty provided by Construction Attachments Inc. hereunder shall extend for a period of (12) months from the date of sale by the dealer to the buyer, as determined by the date of dealer's invoice for the products to the buyer either by facsimile or mail not later than (15) days after the date of sale. Followings are the parts in the category of warranty applied.

• Cylinder • Head Cap • Front Head • Piston • Control Valve Assembly • Cylinder Bushing • Bracket Body • Accumulator Body & Cover

WARRANTY EXCEPTIONS The warranty shall not apply in the following circumstances, even if within the above warranty period. 1. The damages caused by excessive blank hammering 2. Any scratches on piston, cylinder & control valve that results in using contaminated hydraulic oil coming from

the host machine. 3. Damage resulting from the poor working performance of an old host machine. 4. Damage caused by improper storage of the breakers in wet conditions for an extended period of time. The

breaker has to be inspected before placing back into service after being stored for a period of longer than (2) weeks.

5. Wear parts are excluded from warranty period. 6. A/S expenses such transportations, meals etc to be paid by dealer. WEAR PARTS WARRANTY The warranty period is (6) months for the following wear parts:

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• Through Bolt Assembly • Gas Valve Set • Front Cover • Round Bushing • Hose Adaptor • Hose & Piping Kit Parts • Bracket Bolts, Pins & Bushings • Accumulator Bolts & Diaphragm

NOTE Warranty is not applied to any damages or defects incurred through the misuse of this attachment as described in this manual. Parts that are deemed as normal “Wear Parts” are not included into warranty PARTS NOT INCLUDED IN WARRANTY The followings parts are excluded from any warranty claims.

• Seal Kits • Gas Bottles • Chisel Pin • Stop Pin

CHISEL WARRANTY The chisel is guaranteed from defects in material and workmanship as described in the chisel warranty as described in the operators manual. THE CONTENTS OF WARRANTY All delivered products will be checked for defects, damages or missing parts to assure performance upon arrival. The dealer has to inform Construction Attachments Inc. with a written claim on any missing or damaged parts within (14) days after receipt of products. Construction Attachments Inc. will not warrant any damage that is occurred by improper or careless handling, excessive stress, normal wear and tear or similar cases not due to faults of Construction Attachments Inc. (Please refer to the exception of warranty) The dealer will keep the damaged products for a maximum period of (1) year for inspection and analysis by Construction Attachments Inc. Reimbursement will be carried out within (15) days after warranty has been granted.

Manual Operador Martillo Baker

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