KF3BM Nordco Hydraulic Hammer Owner’s Manual l · KF3BM Nordco Hydraulic Hammer Owner’s Manual...

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This manual applies to Kent Hammer S/N 5001 & Above • The policy of Kent Demolition Tools is one of continual improvement. We reserve the right to change

design, materials, or specifications at any time, without notice or creating any obligation to previous or future customers.

• The information contained in this manual is provided at no charge to the customers of the Kent Demolition

Tool Company, a Division of Gougler Industries, inc., Kent, Ohio. • We hereby grant to our customers the right to reproduce individual pages, electronically or by photocopy,

when used in support of the Kent product described herein, provided that no changes are made to the material information, no reproductions are sold, and no part of this manual is incorporated in any publication without the specific written permission from the Kent Demolition Tool Company.

Last Revision: November 2005

NOV/2005 Preface – Page #1

KENT'S COMMITMENT TO ITS CUSTOMERS

For over 45 years, Kent has been dedicated to designing and manufacturing a broad

line of top-performing, quality tools for the demolition and construction industries. We are continuously gathering experience from many work areas and using that experience to manufacture the best tools available to meet the needs of ever-changing market requirements.

Kent demolition tools have been designed from the inside out to deliver the rugged and

dependable day-in and day-out performance you need to get the job done, to minimize downtime, and to keep the job moving on budget and on schedule. With our wide choice of hydraulic hammers, pneumatic hammers, concrete crushers, pedestal units, compactor/drivers, hand-held tools and accessories, you can always choose the right combination for maximum job productivity.

Kent supports you every step of the way with things like on-site engineering for custom

design work, two strategically located warehouse facilities with extensive tool inventories assuring on-time deliveries, experienced parts personnel who know how to listen, and a nationwide distribution network for fast-access sales and service. These are just a few of the reasons to rely on Kent to satisfy all of your demolition requirements.

Sincerely, Kent Demolition Tool Co.

Preface – Page #2 NOV/2005

TABLE OF CONTENTS SECTION A GENERAL INFORMATION 2 HAMMER SPECIFICATIONS 3 SAFETY PRECAUTIONS 4 HAMMER CONSTRUCTION 5 PRINCIPLE OF OPERATION

SECTION B MAINTENANCE 2 LUBRICATION 4 ACCUMULATOR DISASSEMBLY PROCEDURE 8 ACCUMULATOR RE-ASSEMBLY PROCEDURE 10 ACCUMULATOR CHARGING PROCEDURE 14 TORQUE REQUIREMENTS

SECTION C TROUBLESHOOTING

SECTION D PARTS LIST 2 KF3BM HAMMER PARTS 4 KITS: 4 HAMMER LIFTING EYE KIT 5 HAMMER CHARGE KIT 6 ACCUMULATOR KIT 7 SEAL KIT

NOV/2005 Section A – Page #1

SECTION A

GENERAL INFORMATION

Section A – Page #2 NOV/2005

KF3BM 350# Class Hammer

SPECIFICATIONS:

Mounting Style . . . . . . . . . . . . . . . Bare Hammer Power Unit

Weight . . . . . . . . . . . . . . . . . . . . . 162 lbs. (74 Kg)

Length . . . . . . . . . . . . . . . . . . . . . 33.3 in. (845 mm)

AEM Impact Energy Rating . . . . . . 162.0 ft./lbs. (219.6 joules)

AEM Test Flow Rate . . . . . . . . . . . 8.96 GPM (33.92 L/min)

AEM Test Frequency . . . . . . . . . . . 1158.60 BPM (19.31 Hz)

AEM Supply Line Pressure . . . . 1976.86 PSI (136.30 Bar)

Blows/Minute . . . . . . . . . . . . . . . 700 ~ 900

Acceptable Oil Flow. . . . . . . . . . . . 6.5 ~ 10.5 G.P.M.

Operating Pressure . . . . . . . . . . . . 1450 ~ 2500 P.S.I.

Chuck Diameter . . . . . . . . . 2 in. (52 mm)


SAFETY PRECAUTIONS

Before installation or operation of the hydraulic hammer, the operator and maintenance

personnel should read and understand the following safety precautions:

• The safety alert symbol ! means ATTENTION! Your safety is involved!! • No bystanders are allowed in the vicinity of the hammer while it is in use. • Stay clear of the hammer while it is in operation. Flying objects can cause severe injuries, or

even death. • Always wear safety glasses and ear protection when operating the hammer. • Always wear safety glasses during installation, service or any activities associated with the

hammer. • Operate the hammer only when the operator is seated with full control of the machine. • Use the hammer for its intended purpose only. • When installing or removing the hammer, keep hands and fingers clear of the mounting pin

holes and linkage. • Make frequent inspections of the hammer and base machine as described in the "Daily

Inspection" section of this manual. • Do not make any alterations to the hammer without the authorization of Kent's Product Support

Department. • Anytime service is performed on the hammer, hydraulic pressure in the line must first be

released. Then disconnect the hydraulic lines themselves. • Never disassemble the hammer without first releasing the gas charges. Failure to comply can

result in serious injuries or death. • Use only Kent/Nordco replacement parts.

• Never use hands to search for hydraulic fluid leaks, use a piece of paper or cardboard.

Escaping fluid under pressure can be invisible and can penetrate the skin and cause a serious injury. If any fluid is injected into your skin, see a doctor immediately. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.


GENERAL CONSTRUCTION OF THE

HAMMER

1. ACCUMULATOR The accumulator stores hydraulic fluid for use during the hammering cycle. It also absorbs any pulsations seen by the hydraulic circuit. 2. BACKHEAD The hydraulic ports (pressure and return) are built into the backhead. 3. THROUGH BOLTS The three (3) major parts of the hammer, the front head, cylinder and the backhead, are secured by four (4) through bolts 4. VALVE The valve fits over the piston inside the cylinder, and controls the piston reciprocation. 5. PISTON The kinetic energy of the piston during the operation of the hammer, is converted into impact energy when it is transmitted to the working steel. 6. CYLINDER The hydraulic circuit for reciprocating the piston is built into the cylinder. The cylinder is the heart of the hammer. 7. FRONTHEAD The fronthead supports the entire hammer. Due to the shock transmitted by the working steel, the thrust ring and thrust bushing are built-in. 8. ANVIL The anvil transmits the piston’s impact energy onto the spike head.


PRINCIPLE OF OPERATION

The impact energy is a product of the force acting on piston and the length of its stroke. The

piston is powered by the direct action of the hydraulic oil pressure and flow to the hammer. The following illustration is a simplified sketch of the hydraulic oil porting of the hammer. Area

(A1) of the piston is larger than area (A2) of the piston. Area (A1) is alternately connected to the pressure (IN) or the return (OUT) lines of the hammer by the valve. Area (A2) is always connected to the pressure (IN) line. Area (A3) is an unpressurized chamber which allows for the free movement of the piston.

The piston rises when area (A1) is

connected to the return (OUT) line. The oil pressure on area (A2) is greater than the oil pressure acting on area [A1], driving the piston upward.

At the end of the return stroke, the

valve shifts, diverting the oil to area (A1) of the piston. The oil pressure drives the piston downward striking the working steel. The kinetic energy of the piston at this point is transferred to the working steel. The working steel is then driven into the material to be broken. At this point, the valve shifts back to its original position, causing the cycle to repeat.

To maintain continuous oil flow during

the valve shift, a bladder-type accumulator is utilized. The accumulator acts as a variable size reservoir for the oil, allowing for continuous oil flow during the time the piston is changing direction. This reduces the pulsations in the hydraulic system.


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NOV/2005 Section B – Page #1

SECTION B

MAINTENANCE

Section B – Page #2 NOV/2005

LUBRICATION Kent's KF3BM hydraulic hammer is equipped with one (1) grease fitting. This fitting is located on the front bushing, near the anvil (refer to the illustration below). Lack of lubrication can cause failure of the anvil, piston or shorten the life of the seals. An NLGI NO.2 grease is recommended.

• The fronthead should belubricated daily. Grease morefrequently, if needed, but do notover-load the tool with grease.

• Make certain the anvil is fully

engaged prior to greasing.


Accumulator Disassembly/Assembly: Before you attempt to disassemble the accumulator, you should become familiar with the components of the accumulator. They are as follows:

General Note: When disassembling the accumulator, inspect all parts for wear and replace as necessary before reassembly.

Tools required for this procedure:

Adjustable or 22mm wrench 5mm Hex key (allen wrench) 14mm Hex key (allen wrench) 4# hammer vise 600 or finer grit paper Anti-Seizing Agent (for reassembly) Spanner wrench (for accumulator disassembly and reassembly)


Disassembly Procedures: Discharge the Nitrogen:

ACCUMULATOR IS UNDER HIGH PRESSURE! DO NOT STAND OVER THE CHARGE PORT LOCATED ON TOP OF THE ACCUMULATOR. FAILURE TO

DO SO MAY RESULT IN BODILY INJURY.

1. Remove accumulator plug (on top of accumulator) and valve cap (on side of accumulator) using 22mm or adjustable wrench.

2. Using a 5mm allen wrench, slowly unscrew the needle valve a few turns at a time. Wait a few seconds after each series of turns. This will discharge gas from the accumulator. DO NOT REMOVE VALVE AT THIS TIME! NOTE: If foam begins to exit the hole in the top of the accumulator cover this signals that the diaphragm has been ripped and hydraulic oil has entered the top of the accumulator. After the nitrogen gas has been thoroughly bled from the system, continue unscrewing the needle valve. Set aside for inspection and cleaning.


Disassembly Procedures (Continued):

3. Using a 14mm allen wrench, remove the accumulator by removing the set screws holding the accumulator to the back head. (Note: If you have the optional lifting eye kit installed this must be removed as well.)

4. Turn the accumulator upside

down and insert it into a vise. Lock it securely. Do NOT use the large nut in the center of the accumulator body to loosen the body. Step 5 will instruct you on how to properly remove the body from the cover.

Removal of the nut will cause damage to the accumulator and cause it to malfunction. In the even that you have tried to turn the nut:

• Continue to rotate the nut until – when you look into the rings of the accumulator body – the diffuser rings are fully open and there are no webs blocking the holes.

• Tackweld the nut to the accumulator body.


Disassembly Procedures (Continued): 5. Using a spanner wrench (Nordco

P/N 4011560), insert the 4 pins on the wrench into the matching holes at the bottom of the accumulator. This may require tapping the wrench pins – with the hammer butt - into their corresponding holes.

6. Gently tap a 4# hammer on the

wrench handle, moving it in a counterclockwise (CCW) direction. This is done only until the accumulator body has been loosened to the point you can turn it by hand. At this point remove the spanner wrench by gently tapping up with the hammer butt. Be careful not to use too much force to remove wrench. This may strip the threads on the accumulator body.

7. Remove the body and

diaphragm. Dispose of the diaphragm.


Disassembly Procedures (Continued): 8. Wash the accumulator body and cover in solvent. 9. Inspect the inside of the accumulator cover and body for burrs or nicks. If burrs

are found, they can be removed by using 600 grit or finer paper. If nicks are found, replace the part.

If nicks or burrs are left inside the accumulator, damage to the diaphragm will occur during charging procedures.

10. Clean the face of the accumulator. (where it mates to the back head of the

hammer).


Re-Assembly Procedures:

Apply a coat of anti-seize agent to prevent scores to threaded pant of accumulator body. Place the new diaphragm carefully to seat in the outer circumferential groove. Lubricate the round notches of the outer circumferential face of the diaphragm with high-quality grease. Lubricate the thread of the outer circumferential part of the accumulator body with anti-seize lubricant.

Set the accumulator cover. Clean the inside of the washed accumulator cover with a fresh cloth. Put the accumulator cover onto the accumulator body, and fasten it by turning it by hand. ★ Notice: Be careful not to damage the thread during assembly.

Inspect o-rings on the plug and the valve cap. Replace as required. Reassemble to accumulator cover as shown. Torque valve cap and plug to 110 ft./lbs.


Re-Assembly Procedures:

Charging of nitrogen gas After the accumulator has been reassembled,

loosen the vise, and set it back again with the outside up.

The accumulator can be charged with Nitrogen

gas at this time (following the procedures on page 10) or can be mounted back on the hammer and charged later.

When mounting accumulator to back head, torque

cover bolts to 180 ft./lbs.


ACCUMULATOR CHARGING PROCEDURE To receive the optimum performance from the hydraulic hammer, care must be taken to maintain the proper nitrogen charge in the accumulator of the hammer. To assist with this, a charge kit is available. Refer to Section D, Page 5.

NOTE: The customer supplied nitrogen tank MUST be equipped with a regulator! The following is a step-by-step procedure that should be used to properly charge the accumulator. These are written for use with the charge kit. The accumulator can be safely charged either on or off the hammer, as long as these procedures are followed:

STEP ILLUSTRATION STEP 1 If you haven’t already done so, assemble all items of the Charge Kit with the exception of Items 3 and 4. Note: The charge kit, with the exception of items 3 and 4, is to be stored as a complete unit and does not require disassembly. Make certain that the shut-off valve (12) is fully closed (clockwise). STEP 2 Remove the plug and o-ring from the top of the accumulator cover using a 22mm or adjustable wrench. Replace with Charge Kit Adapter (#3) and O-ring (#4).


STEP ILLUSTRATION STEP 3 Remove the cap (#19) and O-Ring (#20) from the side of the accumulator cover using a 22mm or adjustable wrench.

USE EXTREME CAUTION WHEN HANDLING PRESSURIZED VESSELS!!

STEP 4 Attach the end of the regulator hose (#15) to the regulator on the nitrogen tank and then attach the elbow end (#18) of the charge kit to the charge kit adapter (#3) installed under Step 2.

STEP 5 Set the regulator on the nitrogen tank to 1,100 psi. Using the chart at the right, determine the charge pressure needed for the ambient temperature of the accumulator (not ambient room temperature). This pressure is used for Step 7.

ACCUMULATOR

PRESSURE TABLE

AMBIENT TEMPERATURE

CHARGE PRESSURE

90° ~ 100° F 988 – 1039 PSI

80° ~ 90° F 972 - 1007 PSI 70° ~ 80° F 956 - 991 PSI 60° ~ 70° F 940 - 975 PSI 50° ~ 60° F 924 - 959 PSI 40° ~ 50° F 908 - 943 PSI 30° ~ 40° F 892 - 927 PSI 20° ~ 30° F 870 - 911 PSI 10° ~ 20° F 860 - 895 PSI 0° ~ 10° F 844 - 879 PSI -10° ~ 0° F 828 - 863 PSI


STEP ILLUSTRATION STEP 6 Open the charge valve (21) on the accumulator about one full turn.

STEP 7 Open the valve on the nitrogen tank. Open the shut-off valve (12) gradually, allowing nitrogen to flow into the accumulator until the charge kit pressure gauge (11) reads the pressure determined under Step 5, then close the shut-off valve. STEP 8 Close the charge valve (21) on the accumulator and reinstall the cap (19) and o-ring (20).

STEP 9 Remove the elbow end (18) of the charge kit from the charge kit adapter.


STEP ILLUSTRATION STEP 10 Remove the charge kit adapter (3) and o-ring (4). Reinstall the Accumulator Plug and O-ring.

Step 11 Close the valve on the nitrogen tank and bleed off nitrogen pressure by slowly opening the shut-off valve (12). Once the pressure gauges on the tank read 0 psi, close shut-off valve. The accumulator is now charged. Store the charging kit for later use.


Torque Specifications

As a general rule, all bolts should be torqued in sets, so that the load is divided equally among any bolts that function as a group. All bolts in that group should first be loosened, and then re-tightened in stages, alternately bringing opposing bolts up to the same torque level, until all bolts in the group share the load equally. Continue in the same way, bringing all bolts in that group up to the final torque level specified.

Note: Anvil Top, and Wheel Stud modifications are not shown. Refer to documentation in Section C later in this manual.

NOV/2005 Section C – Page #1

SECTION C

TROUBLESHOOTING

Section C – Page #2 NOV/2005

TROUBLE SHOOTING GUIDE

If a problem occurs with the hammer, it is important to first get a flow and pressure

reading of the hammer circuit. To do this, plumb a flow meter and pressure gauge into the pressure line going to the hammer, locate them as close to the hammer as possible. Once the readings are taken, refer to the following list of problems and possible causes:

Condition Problem Remedy Does not hammer... Supply hoses have been

reversed. Pressure line from pump must be connected to pressure port marked "P". The return line connects to tank port marked "T".

Oil flow is not sufficient to cycle hammer.

Flow test pump circuit. Replace or repair pump, Adjust hammer valve.

Operating pressure not sufficient to cycle hammer.

Check and/or adjust relief settings. Adjust hammer valve.

Supply hoses collapsed, plugged, or leaking.

Replace hose.

Backhead chamber filled with oil.

Replace all hammer seals.

Shuttle valve stuck. Disassemble and clean all valve ports. Replace worn valve.

Screw couplings are faulty Check fillings and replace as needed.

Continued...

NOV/2005 Section C – Page #3

Continued... Condition Problem Remedy Hammer is slow or erratic...

Hydraulic oil temperature is too high.

Oil temperature should not exceed 176°F.

Low oil flow or pressure. Test and repair hydraulic system. Adjust hammer valve.

Accumulator pressure too high.

Adjust pressure to specification.

Too much grease in fronthead.

Remove anvil, and clean fronthead cavity. Do not over-grease.

Anvil is galled or sticking. Hammer should be greased daily. Grease the fronthead with hammer upright, and anvi fully engaged.

Anvil is not fully engaged.

Use correct down pressure. Be sure the anvil and front cover are not worn, and have been properly greased.

Anvil steel does not stay engaged, or extends under load.

Check carrier oil pressure. Adjust to specifications.

Continued...

Section C – Page #4 NOV/2005

Continued... Condition Problem Remedy Hammering is weak... Insufficient oil flow. Adjust control valve to rated

specifications.

Operating pressure is low Check the pump and pressure relief valve.

Oil is contaminated, discolored, or cloudy in appearance

Change hydraulic oil, and filters.

Oil level is low Refill to proper levels.

Return line back pressure is too high

Check filter and hose connections.

Excessive amounts of oil are leaking out from chuck area. Oil flows off end of anvil.

Replace seal kit if oil consumption is greater than 1 pint per hour.

Pressure hose shakes or vibrates excessively...

Accumulator pressure is low. Recharge with nitrogen gas to specifications.

Diaphragm is torn or damaged.

Replace diaphragm, and charge with nitrogen gas to specifications.

Shuttle valve is warped or deformed.

Replace valve shuttle.

• If the cause of the problem still cannot be isolated, contact Nordco Service

(1-800-445-9258) for additional assistance.

NOV/2005 Section D – Page #1

SECTION D

PARTS LIST

Section D – Page #2 NOV/2005


PARTS LIST

ITEM

PART NUMBER QTY DESCRIPTION ITEM PART NUMBER QTY DESCRIPTION

001 KF3-10201 1 Cylinder 026 K154037-10025 1 Spring Pin

002 KHB3R-10106 1 Dust Seal 027 KF3-3021 1 Back Head

003 KHB3R-10107 1 U-Packing 028 K160011-00018 4 O-Ring

004 KF3-10111 1 Seal Retainer 029 K15287 2 Port Adapter

005 KHB2R-10107 1 U-Packing 031 35700832 3 O-Ring

006 KF3-10114 1 Seal Ring 032 1560039 3 GPF Plug

007 K161021-00065 1 O-Ring 033 K084891-01000 1 GPF Plug

008 KHB2R-10120 1 Plug 034 K160011-00008 1 O-Ring

009 K160011-10010 1 O-Ring 035 KF3-36201 4 Through Bolt

010 KF3-10121 4 Bushing 036 KF3-36202 4 Hexagon Nut

011 35700834 4 O-Ring 79140945 1 Accumulator

012 K084891-01000 3 GPF Plug 037 79140943 (1) Accumulator Cap

013 35700831 3 O-Ring 038 79140944 (1) Accumulator Body

014 K154037-10025 1 Spring Pin 039 7296022 (1) Diaphragm

015 Kf4-10231 1 Valve Adjuster 040 35700830 (1) O-Ring

016 KF4-10233 1 Seal Nut 041 1612260 (1) Valve

017 KHB1G-10532 1 Seal Washer 042 23164410 (1) Cap

018 54910560 1 Plug 043 15465 (1) Plug

019 KF3-11101 1 Piston 044 11762 (1) O-Ring

020 KF3-13101 1 Valve 045 35700833 (2) O-Ring

201 KF3-20202 1 Fronthead 046 K102032-16060 (4) Socket Bolt

022 3308026 1 Rod Pin (Retainer) 047* 4011560 1 Spanner Wrench

023 3308031 1 Stop Pin 048 22880062 1 Anvil Bushing with Stud

024 1560036 1 Screw Plug 049* 22880060 (1) Anvil Bushing

025 3801280 1 Grease Nipple 050* 2480325 (1) Stud

( ) Bracketed quantities indicate items included with the prior assembly.

*Not Shown Part of Seal Kit 68010009


Kits Available for Kent Hammers

98410212 Hammer Lift Eye Kit

ITEM PART NUMBER QTY DESCRIPTION

--- 98410212 1 Hammer Lift Eye Kit

1 3767080 2 Soc Head Capscrew, M16 x 80 –12.9

2 86038990 4 High Strength M16 Flat Washer

3 31920262 1 Hammer Lifting Eye

4 3069437 2 H-Collar Lockwasher M16

Note: When replacing accumulators, keep all hardware For remounting the lifting eye.

- Kits continued on following pages -


98410014 Hammer Charge Kit

CHARGE KIT PART NO. : 98410014

ITEM PART NO. QTY DESCRIPTION

1 10299600 1 CHARGE KIT ADAPTER 2 3034 1 O-RING 3 10299610 1 CHARGE KIT ADAPTER 4 1829 1 O-RING 5 K21806 1 HOSE ASSEMBLY 6 K08897 1 1/4" NPT FEMALE TEE 7 K08977 1 1/4" NPT PIPE NIPPLE 8 K15341 1 1/4" NPT Q.D. NIPPLE 9 K15340 2 1/4" NPT Q.D. COUPLER 10 K15350 1 200 PSI PRESSURE GAUGE 11 K15351 1 1000 PSI PRESSURE GAUGE 12 K15348 1 1/4" NPT SHUT-OFF VALVE 13 K04692 1 1/4" NPT X 4 JIC ADAPTER 14 K15339 1 4 JIC CAP 15 K21373 1 HOSE ASSEMBLY 18 15374 1 4 JIC SWIVEL ELBOW

This charge kit works on all Nordco machines equipped with Kent Hammers. Items 1 & 2 are included in the kit, but work with the larger Kent Hammer, not the KF3BM.


Accumulator Kit

ACCUMULATOR KIT PART NO. : 79140945

ITEM PART NO. QTY DESCRIPTION

1 79140943 1 Accumulator Cap 2 23164410 1 Cap 3 35700833 2 O-Ring 4 1612260 1 Valve 5 11762 1 O-Ring 6 7 7296022 1 Diaphragm 8 79140944 1 Accumulator Body 9 35700830 1 O-Ring


68010009 SEAL KIT

ITEM

PART NUMBER QTY DESCRIPTION

002 KHB3R-10106 1 Dust Seal

003 KHB3R-10107 1 U-Packing

005 KHB2R-10107 1 U-Packing

006 KF3-10114 1 Seal Ring

007 K161021-00065 1 O-Ring

008 KHB2R-10120 1 Plug

009 K160011-10010 1 O-Ring

010 KF3-10121 4 Bushing

011 35700834 4 O-Ring

013 35700831 3 O-Ring

017 KHB1G-10532 1 Seal Washer

018 54910560 1 Plug

024 1560036 1 Screw Plug

028 K160011-00018 4 O-Ring

031 35700832 3 O-Ring

034 K160011-00008 1 O-Ring

040 35700830 (1) O-Ring

044 11762 (1) O-Ring

045 35700833 (2) O-Ring


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