This document is a repair manual for Krupp hydraulic hammers, specifically the HM 1000 and HM 1000 Marathon® models. It provides comprehensive instructions for dismantling, assembling, checking, and repairing various components of the hydraulic hammer.
Function Description:
The Krupp HM 1000 and HM 1000 Marathon® are hydraulic hammers designed for heavy-duty demolition and breaking tasks. They operate by converting hydraulic power into percussive energy, delivering powerful blows to break materials such as rock, concrete, and asphalt. The manual covers the entire lifecycle of the hammer from a maintenance perspective, ensuring its operational safety and longevity. Key components include a percussion mechanism, high-pressure accumulator, control slide valve, AutoControl valve, cylinder, percussion piston, sealing bush, external-thread flange, DustProtector, and various guide and damping elements. The Marathon® version includes a ContiLube® II system for automatic lubrication.
Important Technical Specifications:
- High-pressure accumulator: Capacity of 0.9 liters, maximum permissible operating pressure of 200 bar (2900 psi).
- Tools:
- Sledgehammers: 2 kg (Pt.-Id.-No. 1031811) and 4 kg (Pt.-Id.-No. 1146433).
- Grease gun: cpl. (Pt.-Id.-No. 3034567).
- Spanners: Slugging ring spanner size 55 (Pt.-Id.-No. 0439439), Heavy-duty box spanner size 55 (Pt.-Id.-No. 0478217), Jaw spanner size 41/46 (Pt.-Id.-No. 0430613), Socket spanners sizes 24/27 (Pt.-Id.-No. 0431002), 22 (Pt.-Id.-No. 1031835), 14 (Pt.-Id.-No. 3031396), Claw spanner size 46/50 (Pt.-Id.-No. 0478861).
- Allen keys: sizes 22 (Pt.-Id.-No. 0209445), 19 (Pt.-Id.-No. 0209253), 17 (Pt.-Id.-No. 0209252), 14 (Pt.-Id.-No. 0204963), 12 (Pt.-Id.-No. 0209251), 5 (Pt.-Id.-No. 0209249).
- Power screwdriver insert: size 55/1 1/2" (no Pt.-Id.-No. provided).
- Adapters: 1" J/1 1/2" A (no Pt.-Id.-No. provided) and 3/4" J/1" A (no Pt.-Id.-No. provided).
- Screwdriver: 8 mm (Pt.-Id.-No. 328143).
- Torque wrench: 140-760 Nm / 3/4" (no Pt.-Id.-No. provided).
- Toolbox 3 (Pt.-Id.-No. 3034016):
- Dimensions: Length 760 mm, Width 215 mm, Height 250 mm.
- Contents: Toolbox, empty (Pt.-Id.-No. 2267014), Chisel paste (Pt.-Id.-No. 3066065), Nitrogen cylinder 2l (Pt.-Id.-No. 3034504), Filler valve (Pt.-Id.-No. 1329516), Test pressure gauge (Pt.-Id.-No. 1329518), Hose (Pt.-Id.-No. 1329517), Test gauge HM 1000 (Pt.-Id.-No. 3002794), Pin punch d=15.5 L=130 (Pt.-Id.-No. 1848819), Claw spanner size 50 with tommy bar (Pt.-Id.-No. 0478861), Screwdriver size 5 (Pt.-Id.-No. 3066376), Hexagonal head bolt M 12x150 (Pt.-Id.-No. 0103866).
- Accumulator filling device (Pt.-Id.-No. 0920415): Includes pressure gauge, check valve, Phillips screwdriver, tommy screw, filling hose (Pt.-Id.-No. 1329805), Phillips screw insert (Pt.-Id.-No. 1329890), and mushroom head adapter (Pt.-Id.-No. 1329889).
- Heli-Coil tools: Various screw taps, threaded inserts, and screw-in tools for M14, M16, M20, M30, and RD 36x5 threads, used for cylinder cover, high-pressure accumulator, and lower hammer part.
- Fitting aid for percussion piston: Eye bolt (Pt.-Id.-No. 0206700).
- Press-out aid for wear bushes: Consists of grip, screw, and press-out element (no Pt.-Id.-Nos. provided for individual components).
- Operating media/consumables: HP oil HLP 32 (higher viscosity for warmer climates), high-performance bearing grease with solids content (Krupp chisel paste), Nitrogen N2 (from green cylinder only), abrasive polishing paper, grain 600.
Usage Features:
The manual emphasizes the importance of using genuine Krupp spare parts and having repairs carried out by Krupp-trained specialists to maintain operational safety. It highlights specific differences between the HM 1000 and Marathon® versions where applicable. The document provides detailed, step-by-step instructions for all repair procedures, including:
- Dismantling: Removing the working tool, percussion mechanism, high-pressure accumulator, control slide valve, AutoControl valve, perforated disk, cylinder cover, percussion piston, sealing bush, cylinder, external-thread flange, DustProtector, locking pins, and plastic bushes.
- Assembling: Fitting the cylinder, percussion piston, sealing bush, cylinder cover, AutoControl valve, perforated disk, control slide valve, high-pressure accumulator, external-thread flanges, filling the piston accumulator, fitting the percussion mechanism, connecting ContiLube® II (for Marathon®), fitting the working tool, and fitting the DustProtector.
- Checking: Inspecting the hammer box for cracks and indentations, wear to the bottom plate, elastic pad, damping elements, guide plates, upper guide, and dust collar.
- Changing seals: Instructions for cylinder seals, seals between cylinder and cylinder cover, seals on the external-thread flange, seals on the control casing cover, seals on the high-pressure accumulator, and seals on the sealing bush.
- Repair work: Procedures for changing Allen screws on the high-pressure accumulator, changing the high-pressure accumulator itself, changing tie rods, removing scores from control slide valve and bore, removing scores on percussion piston and cylinder bore, replacing retainer bars and working tool, changing wear bushes, replacing the complete hammer box, replacing guide plates and damping elements, replacing the dust collar, replacing the wear protection set, replacing the DustProtector, repairing cracked welds, replacing the bottom plate, reworking retainer pins, weld seam preparation, preheating temperature, fillers, and post-treatment of welds.
Maintenance Features:
The manual is primarily a maintenance and repair guide. It provides crucial safety information and instructions to prevent accidents, injuries, and damage to the equipment.
- Safety:
- Always depressurize the piston accumulator before dismantling, using only the specified nozzle for the filling/test hose.
- Never use nails, screwdrivers, or similar objects to bleed off gas.
- Never dismantle a hot hydraulic hammer.
- Collect and dispose of oil correctly.
- Fill the piston accumulator only with nitrogen from a green cylinder; never use air or oxygen.
- Use Allen screws with a material quality of σE = 640 N/mm² (material quality 8.8) when attaching adapters.
- Familiarize with the repair manual and relevant regulations (EC machinery directive 98/37/EG, national accident prevention regulations, and pressurised vessel regulations).
- Use the lug provided and hoisting equipment with sufficient capacity for lifting/transporting.
- Never stand beneath hoisted loads.
- Secure the hydraulic hammer against falling over.
- Wear protective glasses when fitting or removing the working tool.
- Ensure the repair area is clear and accessible.
- Tooling: A comprehensive list of general and special tools, including a dedicated Toolbox 3, accumulator filling device, power wrenches (electronic or hydraulic), Heli-Coil tools, fitting aid for the percussion piston, and a press-out aid for wear bushes, is provided to facilitate proper maintenance.
- Consumables: Specific hydraulic oil (HP oil HLP 32), high-performance bearing grease (Krupp chisel paste), nitrogen, and abrasive polishing paper are specified for maintenance tasks.
- Inspection: Regular checks for cracks, wear, and proper functioning of various components are detailed, ensuring timely replacement or repair.
- Sealing: Instructions for changing seals are critical for maintaining hydraulic integrity and preventing leaks.
- Welding: Detailed procedures for repairing cracked welds, including preparation, preheating, fillers, and post-treatment, are included for structural repairs.
Need help?
General
To Next Page