Testing and Adjusting

Pre-delivery systems set up

Relief Valve Crack Point
Transducer Tests
Basic Trouble Shooting

Hammer Delivery
Service Record

Testing and Adjusting

Critical
Information

HAMMER DELIVERY
SERVICE RECORD

DLR CODE

HAMMER MODEL

SERIAL NO.

HOURS

DELIVERY DATE
/
/
WEIGHT
HOURS

CARRIER
IDENTIFICATION:

MAKE

MODEL

SERIAL NO.

INSTALLATION
INFORMATION:

MOUNTING BRACKET:

CAT DLR

CONNECTING HOSES: CAT DLR

TOOLS: BLUNT CHISEL MOIL OTHER TYPE

APPLICATION:

QUARRY DEMOLITION

TUNNELING

Can be used to speed up trouble

shooting process
Run all tests at:

OTHER

High Idle

TEST DATA
NOTE:

ALL TESTING MUST BE DONE AT MAX. ENGINE RPM,

MAX. POWER LEVEL AND MAX. WORK MODE.

HAMMER DATA:

Accumulator charge (models H115s to H195)

Low pressure accumulator charge (models H45 to H100)
High pressure accumulator charge (models H45 to H100)

BAR/PSI
BAR/PSI
BAR/PSI

Oil flow to hammer (at operating pressure)

Operating pressure at hammer inlet (models H45 to H100)
Low pressure circuit (models H45 to H100)
Pressure in the return line (back pressure )
Line relief valve setting (cracking pressure)
Main relief valve setting of carrier
Hydraulic oil temperature during test

LPM/GPM
BAR/PSI
BAR/PSI
BAR/PSI
BAR/PSI
BAR/PSI
C / F

Flow regulator valve for hammer

Oil cooler on machine
Oil filter in hammer return line

YES
YES
YES

MACHINE DATA:

Keep a copy in machine history

folder for future reference

Highest Power Mode

Attachment Priority Work Mode
Hydraulic Oil at Operating Temp.

NO
NO
NO

SEE SERVICE MANUALS FOR FULL

FORM. (TESTING AND ADJUSTING
SECTION)

Hydraulic Flow Test

Backhoe (H63 - H100)

Testing and Adjusting

Flow
(GPM)

Pressure
@ Flow Meter
Free flow
500
1000
1500
1800
2000
2300
2400
2500

Back Pressure

Oil Temperature

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

Testing and Adjusting

Hydraulic Operating Test

Backhoe (H63 - H100)

Both hammer
test ports are
4BSPP

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

Hydraulic Flow Test

Excavator (H115s - H195)

Testing and Adjusting

Back Pressure Gauge

Flow Meter

Flow
(GPM)

Pressure
@ Flow Meter
Free flow
500
1000
1500
1800
2000
2300
2400
2500

Back Pressure

Oil Temperature

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

Testing and Adjusting

Hydraulic Operating Test

Excavator (H115s - H195)

Test port is
4BSPP
Pressure Gauge

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

Auxiliary Circuit Flow

Test

Testing and Adjusting

Flow Test

Cracking
Point

100

Flow test helps verify that

the relief cracking point is
higher than the combination
of:

60

Hammer Operating Pressure

+ Return line back pressure
+ a Safety Margin.

40
20
0

200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200

Flow (gpm)

80

Flow (gpm)

Pressure (psi)

Transducer
Test

Testing and Adjusting

3000 PSI

CORRECT

PRESSURE

RELIEF SETTING

SAFETY MARGIN
PEAK PSI

AVERAGE OPERATING PRESSURE

PRESSURE

3000 PSI

TIME

INCORRECT

PROBLEMS:
- OVERHEATING
- SLOW HAMMER

PEAK PRESSURE IS HIGHER THAN RELIEF

RELIEF SETTING

PEAK PSI

AVERAGE OPERATING PRESSURE

TIME

Testing and Adjusting

Basic Trouble
Shooting

Hammer Doesnt Start

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

Irregular but Full Energy Blows

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

No Energy, Poor Operation

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

Testing and Adjusting

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

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

Hammer Bleeds Oil

Check Hose Connections
Reseal Hammer

Hammer Moves in Housing

Replace Wear Plates

Basic Trouble
Shooting

Three potential areas for a hammer problem:

1. Carrier System
Electrical.
Relief setting.
Flow setting.
Filter.
2. Hydraulic Kit
Quick coupler failure.
Damaged or pinched hose.
Ball valve closed.
3. Hammer

INSTALLNG A FLOW METER:

Eliminates two of the three possible areas
for problem.
1. Eliminate the carrier as a problem source.
2. Eliminate the hydraulic kit as a problem
source.