Krupp HM 1000 Istruzioni operative
Repair manual
Krupp hydraulic hammers
HM 1000 / 1000 Marathon®
Pt.-Id.-No. 3071017
Valid from:11/98 GB
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Contents
1
Contents
Chapter Title Version Page
1. General........................................................................................11/98............... 1
1.1 Explanation of the symbols in the repair manual .................................................. 2
2. Operational safety.......................................................................11/98............... 1
2.1 General................................................................................................................ 1
2.2 Accident prevention regulations............................................................................ 1
2.3 Tools, measuring and testing equipment............................................................... 2
2.4 Operating media/consumables.............................................................................. 2
3. Tools............................................................................................11/98............... 1
3.1 General tools........................................................................................................ 1
3.2 Toolbox 3............................................................................................................. 2
3.3 Special accessories.............................................................................................. 3
3.3.1 Accumulator filling device..................................................................................... 3
3.3.2 Power wrench....................................................................................................... 4
3.3.3 Heli-Coil tools....................................................................................................... 4
3.3.4 Fitting aid for percussion piston............................................................................ 5
3.3.5 Press-out aid for wear bushes............................................................................... 5
4. Dismantling the hydraulic hammer............................................11/98............... 1
4.1 Removing the working tool................................................................................... 1
4.2 Removing the percussion mechanism of the HM 1000 from the hammer box....... 2
4.3 Removing the high-pressure accumulator............................................................. 3
4.4Removing the control slide valve.......................................................................... 4
4.5 Removing the AutoControl - valve........................................................................ 5
4.6 Removing the perforated disk............................................................................... 6
4.7 Removing the cylinder cover................................................................................ 6
4.8 Removing the percussion piston and sealing bush................................................ 8
4.9Removing the cylinder.......................................................................................... 8
4.10 Removing the external-thread flange.................................................................... 9
4.11Removing the DustProtector................................................................................. 10
4.12 Removing the locking pins for the retainer bars in the lower hammer part............ 11
4.13 Removing the plastic bushes................................................................................ 11
5. Checking the hammer box.........................................................11/98............... 1
5.1 Checking for cracks and indentations.................................................................... 1
5.2 Wear to the bottom plate...................................................................................... 1
5.3 Checking the elastic pad....................................................................................... 2
5.4 Checking the damping elements........................................................................... 2
5.5 Checking the guide plates and the dust collar....................................................... 3
5.5.1 Checking the guide plates..................................................................................... 3
5.5.2 Checking the upper guide..................................................................................... 4
5.5.3 Checking the dust collar....................................................................................... 4
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Contents
2
Contents
Chapter Title Version Page
6. Assembling the hydraulic hammer........................................................11/98... 1
6.1 Tightening torques for screws and screw couplings on the HM 1000..................... 1
6.2 Fitting the cylinder................................................................................................ 2
6.3 Fitting the percussion piston and sealing bush...................................................... 2
6.4Fitting the cylinder cover...................................................................................... 3
6.5 Fitting the AutoControl – valve............................................................................. 5
6.6 Fitting the perforated disk..................................................................................... 6
6.7Fitting the control slide valve................................................................................ 6
6.8 Fitting the high-pressure accumulator................................................................... 6
6.9 Fitting the external-thread flanges........................................................................ 7
6.10 Filling the piston accumulator............................................................................... 8
6.11 Fitting the HM 1000 percussion mechanism in the hammer box........................... 10
6.12 Connecting ContiLube®II to the HM 1000 Marathon®........................................... 11
6.13 Fitting the working tool.......................................................................................... 12
6.14 Fitting the DustProtector....................................................................................... 13
7. Changing the seals.................................................................................11/98... 1
7.1 Changing the cylinder seals.................................................................................. 1
7.2Changing the seals between cylinder and cylinder cover...................................... 3
7.3 Changing the seals on the external-thread flange................................................. 3
7.4 Changing the seals on the control casing cover.................................................... 3
7.5 Changing the seals on the high pressure accumulator.......................................... 4
7.6 Changing the seals on the sealing bush................................................................ 4
8. Repair work.............................................................................................11/98... 1
8.1 Changing the Allen screws on the high-pressure accumulator............................... 1
8.2 Changing the high-pressure accumulator.............................................................. 1
8.3 Changing the tie rods............................................................................................ 2
8.4 Removing scores from control slide valve and bore.............................................. 3
8.5 Removing scores on percussion piston and cylinder bore..................................... 3
8.6 Replacing retainer bars and working tool.............................................................. 4
8.7 Changing the wear bushes.................................................................................... 4
8.8 Replacing the complete hammer box.................................................................... 8
8.9 Replacing guide plates and damping elements in hammer box............................. 8
8.10 Replacing the dust collar in the hammer box........................................................ 8
8.11 Replacing the wear protection set......................................................................... 9
8.12 Replacing the DustProtector................................................................................. 9
8.13 Repairing cracked welds....................................................................................... 10
8.14 Replacing the bottom plate on the hammer box.................................................... 10
8.15 Reworking the retainer pins for the damping elements.......................................... 11
8.16 Weld seam preparation........................................................................................ 11
8.17 Preheating temperature........................................................................................ 11
8.18 Fillers................................................................................................................... 11
8.19 Post-treatment of welds........................................................................................ 11
Authorised dealers and regional service centres
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 1
1
1. General
In order to maintain the operational safety of all versions of the HM 1000 hydraulic hammer, repair work
should only be carried out by Krupp trained specialists using genuine Krupp spare parts. Krupp trained
specialists know which parts need replacing and when.
Although this repair manual applies to all versions of the HM 1000 hydraulic hammer, the manual refers
only to the HM 1000 by way of simplification. Specific differences between the versions are however
highlighted.
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 1
2
1.1 Explanation of the symbols in the repair manual
To emphasise their importance, certain points in the repair manual are marked with symbols, which are
described below.
Theses passages contain information on the
correct use of the hydraulic tool and are aimed at
avoiding mistakes during operation.
Passages marked in this way contain safety
information and instructions aimed at avoiding
damage.
Passages marked in this way contain safety
information and instructions aimed at preventing
accidents and avoiding injury.
Please note!
Warning!
Caution!
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 2
1
2. Operational safety
2.1 General
In order to maintain the operational safety of the
hydraulic hammer, repair work should only be
carried out by trained specialists using genuine
Krupp spare parts. This work should therefore only
be entrusted to Krupp trained specialists who know
which spare parts need replacing and when.
2.2 Accident prevention
regulations
To avoid the possibility of injury, please
observe the following instructions
Before starting work:
Please familiarise yourself with the repair manual
and the appropriate regulations before starting
work on the hydraulic hammer.
When using or working on hydraulic hammers in
the countries of the European Union, the
regulations of the EC machinery directive
98/37/EG must be observed and followed, as must
national accident prevention regulations and
regulations covering pressurised vessels.
In countries outside the European Union, the valid
local statutes and regulations will apply.
The hydraulic hammer should only be repaired by
specialists.
When lifting/transporting the hydraulic hammer,
use only the lug provided and hoisting equipment
with sufficient capacity.
Clear hand signals must be agreed on with the
hoist operator beforehand.
Never stand beneath hoisted loads.
Stand the hydraulic hammer in a suitable device
and secure it against falling over.
The repair area must be clear and easily
accessible.
Always wear protective glasses when fitting or
removing the working tool since metal splinters
may fly off when hammering out the locking pins.
Working tools should only be fitted as described in
the operating manual.
The hammer's integrated piston accumulator is
pressurised.
Before dismantling the hydraulic hammer and
before removing the complete filling valve “G”,
the piston accumulator must be fully
depressurised.
Never use nails, screwdrivers or similar objects to
bleed off the gas since this would damage the
filling valve. Bleed off the gas using only the
nozzle of the filling/test hose.
Never use your fingers to check the alignment of
the working tool recesses to the oblong holes for
the locking bars.
Never dismantle a hydraulic hammer which is still
hot from running as there is a high risk of injury
through burns. Always wait until the hammer has
cooled down before dismantling it. Collect any oil
which runs out and dispose of it correctly.
The piston accumulator must only be filled with
nitrogen from the green cylinder.
Make sure that no other gas (e.g. air or oxygen) is
allowed into the piston accumulator.
When attaching the adapter use only Allen screws
with a material quality of σs= 640 N/mm2(material
quality 8.8)!
Caution!
Caution!
Caution
Risk of explosion!
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 2
2
2.3 Tools, measuring and
testing equipment
The tools required for dismantling and
reassembling the HM 1000 are to be provided by
the user (see Chapter 3.1).
The special accessories used in this section are
listed in Chapter 3.3
2.4 Operating media /
consumables
Use Comments
HP oil
HLP 32 Running the
HM 1000 In warmer
climates, oils
with a higher
viscosity class
should be used.
High-
performance
bearing grease
with solids
content
Working tool
lubrication Krupp chisel
paste (see
operating
manual)
Nitrogen N2Filling the
- high-pressure
accumulator
– piston
accumulator
Abrasive
polishing
paper, grain
600
Removing
scores
Caution!
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 3
1
3. Tools
3.1 General tools
The tools required for repair work are listed below:
Designation Part ID no. Qty.
Sledgehammer 2 kg 1031811 1
Sledgehammer 4 kg 1146433 1
Grease gun cpl. 3034567 1
Slugging ring spanner size 55 0439439 1
Heavy-duty box spanner size 55 0478217 1
Jaw spanner size 41/46 0430613 1
Socket spanner size 24/27 0431002 1
Socket spanner size 22 1031835 1
Socket spanner size 14 3031396 1
Claw spanner size 46/50 0478861 1
Allen key size 22 0209445 1
Allen key size 19 0209253 1
Allen key size 17 0209252 1
Allen key size 14 0204963 1
Allen key size 12 0209251 1
Allen key size 5 0209249 1
Power screwdriver insert size 55 / 1 ½”1
Adapter 1” J / 1 ½” A1
Adapter ¾” J / 1” A1
Screwdriver 8 mm 328143 1
Torque wrench 140-760 Nm / ¾”1
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 3
2
3.2 Toolbox 3
The tools required for service work on the
hammers are contained in Toolbox 3
Fig. 1
Toolbox 3
Dimensions
Length 760 mm
Width 215 mm
Height 250 mm
Toolbox 3 and contents can be
ordered under part ident. no. 3034016.
Item Qty. Designation Pt. ID no.
-1Toolbox, empty 2267014
1 1 Chisel paste 3066065
2 1 Nitrogen cylinder 2l 3034504
3 1 Filler valve 1329516
4 1 Test pressure gauge 1329518
5 1 Hose 1329517
6 1 Test gauge HM 1000 3002794
7 1 Pin punch d=15.5
L=130 1848819
8 1 Claw spanner size 50
with tommy bar 0478861
9 1 Screwdriver size 5 3066376
10 1 Hexagonal head bolt
M 12x150 0103866 Fig. 2
Service tools
Repair manual HM 1000 / 1000 Marathon®
Version 11/98
Chapter 3
3
3.3 Special accessories
This chapter lists the special tools and apparatus
which can be purchased from Krupp Berco
Bautechnik to equip the workshop.
3.3.1 Accumulator filling device
The tools listed in the table below are used to fill
the high-pressure accumulator. The filling process
also requires the nitrogen cylinder (2/2) and the
filler valve (2/3) from Toolbox 3.
Item Designation Pt. ID no.
Filling device cpl. with
pressure gauge, check
valve, Phillips screwdriver
and tommy screw, as well
as items 1 to 3
0920415
1Filling hose 1329805
2Phillips screw insert 1329890
3Mushroom head adapter 1329889 Fig. 3
Accumulator filling device
Questo manuale è adatto per i seguenti modelli
1
Indice
