OPERATIONAL MANUAL - Comet Breaker:World`s Most Powerful
Contents
1. N2 gas cylinder Hose 3 way valve connection part assembly N Hande O ring Bushing plug IU Charging Valve O ring Cap Selection of hydraulic oil determines the efficiency of the hydraulic breaker performance Please consult with our service station under following conditions When used in special regions where climate is severe e g extremely cold or hot weather When recommended Comet hydraulic oil are not available When hydraulic oil supplied Hydraulic Oils and Greases Recommended for Hydraulic Breaker by Comet LUBE amp SPEC Hydraulic Oil Grease MANUFACTURE ISO VG 46 ISO VG 32 ISO VG 46 NLGI No MOBIL GREASE MOBIL DTE25 MOBIL DTE 24 MOBIL DTE 15M MOBIL MOBIL SHC 525 MOBILTH SHC 220 MOBIL EAL SYNDRAULIC 46 LG CALTEX RANDO HD 46 RANDO HD 32 RANDO HD CZ MOLYTEX EP2 BP ENERGOL HP 46 ENERGOL HP 32 ENERGOL HP 46 SHELL Synthetic lubricant Environmentally friendly synthetic lubricant e Oil Contamination TELLUS 46 TELLUS 32 TELLUS T 46 RETINAX HDX 2 Contaminated oil results in malfunctions of the breaker as well as the base machine and cause damage to parts Pay special attention to oil contamination Contaminated oil should be changed without any delay When changing oil thoroughly wash oil tank cylinder and pipes Cleaning or replacing oil filter also requires check for oil contamination Replacement of filter after first 50 hours and every 100 hours th2. a YA 27 e Do not operate the breaker in water and mud When rocks are not broken after more than one minute s Do not operate breaker when all components except tool are immersed in water and mud Piston and similar components may gather rust and become a damaged breaker at an early 5 ma omms OA s _ m e Do not allow the breaker to fall to break a rock Falling down the breaker will apply excessive force to the breaker or the base machine causing damage to many parts of the breaker and the base machine e Do not hammer with base machine cylinders moved to stroke end Hammering with each base machine cylinder moved to stroke end a condition that the cylinder is fully extended or retracted will do considerable damage to the cylinder and each part of the base machine 28 e Do not lift things with the breaker Lifting materials by hanging wire in the bracket or tool not only causes damage to the breaker but also is very dangerous when operating e Warm up base machine engine prior to operation Especially in winter the base machine engine should be warmed up for five to ten minutes 30 C 40 C 86 F 105 F before breaker operation Follow the instruction book for base machine to warm up the engine e Do not touch tool for breaker working While the breaker is working high temperature of the tool will be generated e Whe
3. Operation WY lever hy Hydraulic breaker 2 HYDRAULIC PIPE LINES FOR EXCLUSIVE USE Operation of the hydraulic breaker requires installation of hydraulic pipe lines for exclusive use of the hydraulic breaker As hydraulic pipe lines vary depending on base machines our service engineer must first check hydraulic pressure oil capacity pressure loss and other conditions of the base machine before installing hydraulic pipe lines Use only genuine parts in case of replacement because hydraulic pipe lines hoses pipes and fittings are made of materials carefully selected in consideration of durability THE HYDRAULIC SYSTEM TO THE BASE MACHINE MUST BE CHECKED BY AN AUTHORZED TORPEDO SERVICE ENGINEER BEFORE FIRST USE AND AFTER ANY MODIFICATIONS MAKE SURE THAT THE BREAKER VALVE OF HYDRAULIC SYSTEM IS PROPERLY SET 14 v Filter Low pressure High pressure Cable Control pedal for breaker i E dens i A Hydraulic Hydraul Control valve for breaker u ydraulic PA T Pump Pump L ERN Tank 3 CHECKING BEFORE INSTALLING INSTRUCTIONS 1 CHECK THE SPECIFICATIONS SECTION OF THIS MANUAL TO DETERMINE CORRECT BACKHOE AND EXCAVATOR SIZES HYDRAULIC PRESSURE AND HYDRAULIC FLOW REQUIREMENTS 2 IF HYDRAULIC PRESSURE HYDRAULIC FLOW ARE EXCEEDED THE BREAKER WATTANTY IS NOT APPLIED CHECK THE NITROGEN GAS BACK HEAD AND ACCUMULATOR BE SURE THE FLUID IN THE HYDRAULIC SYSTEM
4. Breaker COMET a OPERATIONAL MANUAL 8 m N s osz CM10 CM20 CM30 CM40 40BL CM70 CM100 CM150 0 I3WOD2 5 IE S 13W05 ov 13 402 SS E17 09 ME PI CM160 CM170 CM200 CM230 CM250 CM350 CM360 lt 04 I3WOD oSv 1AWOD lt LAaWO gt D 051 LINO lt 04113009 CM400 CM450 CM500 CM550 CM600 Breaker COMET a OPERATIONAL MANUAL 8 m N s osz CM10 CM20 CM30 CM40 40BL CM70 CM100 CM150 0 I3WOD2 5 IE S 13W05 ov 13 402 SS E17 09 ME PI CM160 CM170 CM200 CM230 CM250 CM350 CM360 lt 04 I3WOD oSv 1AWOD lt LAaWO gt D 051 LINO lt 04113009 CM400 CM450 CM500 CM550 CM600 COMET HYDRAULIC BREAKER OPERATION MANUAL amp PART LIST COMET INC COMET TECHNOLOGY amp ATTACHMENT 1 Safety Precautions This manual contains safety operation and routine maintenance instructions It does not contain assembly and disassembly service procedure instructions If needed complete disassembly and assembly instruction are contained in the service manual which can be ordered from your COMET Hydraulic breaker authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROER REPAIR OR SERV
5. set by COMET When contamination is excessive drain and flush the hydraulic oil tank and fill it with new oil Missing rubber Rubber plugs A seriously damaged part plugs and snap u Snap rings must be replaced rings Silence type breaker Check every 3 month ifthe If it is worn too mush or Clearance of wear plate guide wear plate guide plate damaged replace the parts plate cushion etc cushions are good or not 37 3 REGUALR BREAKER INSPECTION AND MAINTENANCE Regular inspection is essential for keeping hydraulic breaker operating in the best condition consult with the Comet service station for regular inspection and maintenance Customers are recommended to contact the service station for inspection within six months after delivery 4 REPLACEMENT OF TOOL Tool is deformed of burrs produced in a long term use When a tool tip is worn out tool is liable to slip Then sharpen the tool tip Grinding the tool tip many times to sharpen the edge however it will make a heat treated hardened surface layer disappear and it will wear out the tool rapidly In this case replace with a new tool If a gap between tool and front cover ring becomes large piston fails to fit in tool resulting in damage When the gap is found in over 9mm replace thrust ring together with the tool Replacement Order Remove steel plug or snap ring and tool pin in order with a 330mm long steel bar W
6. 4 6 6 9 6 11 6 11 15 18 18 25 x Description kg 1863 1843 2018 2298 2490 2742 3180 3012 3980 4100 BOX TYPE Ib 4107 4063 4449 5066 5490 6045 7011 6640 8775 9039 Operating Weight kg 1862 1802 2000 2270 2498 2753 2980 3030 3820 4000 TOP TYPE cod Ib 4105 3973 4409 5005 5507 6069 6570 6680 8422 8819 Ro kg 1862 1530 1690 2144 2340 2375 2980 2650 3725 3909 SIDE TYPE Ib 3373 3366 3726 4727 5159 5236 6570 5842 8212 8618 kg 833 761 946 1128 1082 1325 1412 1453 1726 4720 Weight of Main Body Ib 1836 1678 2086 2487 2385 2921 3113 3203 3805 10406 l min 130 150 130 150 130 150 150 210 150 190 180 240 190 250 200 260 210 290 250 320 Required Oil Folw gal min 34 40 34 40 34 40 40 55 40 50 45 63 50 66 53 69 55 76 66 84 bar 210 210 210 210 230 230 230 230 250 250 Setting pressure psi 3046 3046 3046 3046 3336 3336 3336 3336 3626 3626 bar 160 180 160 180 160 180 160 180 160 180 160 180 160 180 160 180 160 180 170 190 Operating pressure psi 2321 2611 2321 2611 2311 2611 2321 2611 2321 2611 2321 2611 2321 2611 2321 2611 2321 2611 2466 2756 Impact Rate bpm 400 800 400 600 350 550 300 450 350 650 300 450 300 600 250 400 200 350 230 320 mm 25 25 25 25 32 25 32 32 32 32 32 Hose Diameter inch 1 1 1 1 14 1 1 1 1 1 1 Tool Diameter mm 135 135 140 150 150 155 160 165 175 180 Tool Length mm 1200 1200 1200 130 1300 1400 1400 1400 1400 1600 Applicable carrier
7. During assembly from lubrication oil amp anti rust oil applied D Between main valve amp Oil leakage from reassembly NORMAL surface of cylinder of breaker after overhaul Clean oil Check that seal is damaged Loosen bolts Replace with new seal E Between cylinder and Oil leakage Loose tie rod nuts back head RETIGHTEN Oil leaks again REPLACE Damaged o ring F Between cylinder and Oil is leaking Loose plugs assembled on the front head surface of cylinder RETIGHTEN Replace damaged seals 45 11 Maintenance Intervals NOTICE Before hydraulic breaker operation be sure to check the following points Every 3 hours Apply the grease in front head Check hydraulic oil temperature Piping and hose connections and working condition Check tightness of fasteners Every 10 hours or Daily If rough skin on the tool and tool pins have found its must be removed Check the nitrogen gas pressure in back head Retighten the bracket bolts Every 50 hours or Weekly Check the clearance between tool and front cover Check hydraulic hoses Retighten the through bolts Every 1000 hours or Six 6 Months Factory inspection by authorized service personnel recommended All hydraulic pipe and hose connections Hose interference from carrier movement Conditions of oil filter accumulator diaphragm through bolts and tool pins Check top buffer amp
8. way valve assembly Remove the cap from the accumulator and tighten the charging valve fully Check if Orings are installed to the bushing Remove the plug and screw the bushing Loosen the accumulator charging valve after checking if bushing is installed to the 3 way valve assembly Turn the handle of the N2gas cylinder counter clockwise slowly to charge the gas Charge the gas in accordance with the conversion table for charging N2gas pressure to accumulator Turn the handle of the N2gas cylinder clockwise to close the cock Close the accumulator charging valve Loosen the valve of the 3 way valve assembly to discharge the N2gas remaining in the charging hose Remove the charging hose 3 way valve assembly and bushing and tighten the plug and cap Conversion table for charging nitrogen gas pressure to accumulator COMET CM Series Accumulator gas Ambient Temperature C F Pressure 0 32 10 32 20 68 30 86 40 104 kg eni 50 5 61 2 55 58 e Acc sticker A symbol Appears on the accumulator body A CAUTION PRESSURIZED CONTAINER DISCHARGE PRIOR TO DISASSEMBLY DO NOT OPEN WITHOUT READING THE OPERATION MANUAL OR CONSULTING THE AUTHORIZED SERVICE PERSONNEL 20 N2gas charging pressure to Accumulator Nz gas charging pressure kg cm Ambient temperature C Conversion table for charging N2 gas pressure to accumulator 6 HYDRAULIC OIL Selection of oil Handle Adapter Synflex hose
9. 2 GAS PRESSURE TO ACCUMULATOR e STANDARD ACCUMULATOR GAS PRESSURE 55kg cm 780psi AT 20 68 AMBIENT TEMPERATURE DO NOT OVER PRESSURIZE ACCUMULATOR Cautions for charging N2gas to the accumulator Be sure to use the 3 way valve assembly for charging the N2gas If charging gas leaks directly from the cylinder the diaphragm may be broken off e If charging for handing N2gas to only the accumulator make sure that the accumulator body and cover are tightened fully Make sure the cap and valve of the 3 way valve assembly are fully tightened Remove the cap from the accumulator and tighten the charging valve fully Check if O rings are installed to the bushing Remove the plug and screw in the bushing Install the bushing to the 3 way valve assembly Loosen the charging valve gradually The charging pressure is indicated on the pressure gauge Close the valve clockwise when the gas pressure is normal When the gas pressure is higher repeat loosening and tightening the valve assembly The pressure is lowered gradually Loosen the valve of the 3 way valve assembly to discharge the N2gas in the 3 way valve assembly Remove the 3 way valve assembly and tighten the plug and cap Charging of 2 gas into accumulator Connect the charging hose to N2gas cylinder after screwing the valve adapter on to adapter nut and installing to the N2gas cylinder Connect the 3 way valve assembly to the charging hose after unscrewing the cap on the 3
10. E THE GAS CYLINDER AS IT IS HIGH PRESSURIZED CONTAINER 5 USE NITROGEN GAS ONLY 6 SEE CONVERSION TABLE FOR CHARGING N GAS PRESSURE TO BACK HEAD Charging of N2gas into back head 1 Remove gas valve plug 2 Insert 3 way valve with 3 If gas is insufficient adjust to specified valve pressure gauge assembled as shown in the previous page Note 2 Note 1 5 Tighten gas valve plug 4 Adjust the pressure slowly Do not cut O ring decreasing it by using the pressure gauge if gas is sufficient Insert 3 way valve after its handle is fully turned counterclockwise Turn the 3 way valve handle clockwise slowly Stop turning it when the needle of the gauge starts to move If it is turned clockwise too tightly the valve may easily be damaged Pay special attention to ensure that the nitrogen gas is not charged excessively e Conversion table for charging nitrogen gas pressure to back head Depends on the temperature of the back head surface COMET Inward Valve Type Back head gas Ambient Temperature Pressure 40 104 kg cr 17 3 psi 246 COMET Outward Valve Type Back head gas Ambient Temperature Pressure 40 104 kg cr 58 60 620 0 64 6 6 psi 94 17 5 INSPECTION AND CHARGING OF N GAS IN ACCUMULATOR e USE SPECIAL CARE TO HANDLE AND STORE THE N2 GAS CYLINDER AS IT IS A HIGH PRESSURIZED CONTAINER e USE NITROGEN GAS ONLY e SEE CONVERSION TABLE FOR CHARGING N
11. ICE OF THIS BREAKER REPAIRS AND OR SERVICE TO THIS BREAKER MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER General safety precautions The COMET hydraulic Breaker series CM type will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual any decals and tags attached to the breaker before operation Failure to do so could result in personal injury or equipment damage Operate the breaker in accordance with all laws and regulations which affect you your equipment and the work site Do not operate the breaker until you have read the carrier equipment manual and thoroughly understand all safety requirement operation and maintenance instructions Ensure that all maintenance procedures recommended in this manual are completed before using the equipment The operator must not operate the breaker or carrier if any person is found within the danger zone where they may be injured by flying debris or movement of the equipment Know the limitation of your equipment Establish a training program for all operators to ensure safe operation Do not operate the breaker unless thoroughly trained or under the supervision of an instructor Get used to the carrier controls before operating the carrier and the breaker While learning about the breaker and the carrier please do so at a slow pace If necessary set the carrier mode selector to the slow working po
12. IS CLEAN CHECK THE HYDRAULIC FILTER REPLACE THE FILTER IF DIRTY OR DETERIORATE HOSE AND PIPING MUST BE FLUSHING THE CONTAMINATED PART MUST BE CLEANED WITHOUT DELAY HYDRAULIC OIL OR LIGHT OIL IS HIGHLY RECOMMENDED 0 o 15 IMPORTANT THE CIRCUIT RELIEF SETTING PRESSURE IS NOT FIXED HOWEVER IT WILL BE ADJUSTED BY PUMP CAPACITY e Recommended circuit relief setting pressure and back pressure COMET Inward Valve Type CM 10 CM 20 CM 30 CM 35 CM40 40BL CM 55 CM 70 Relief Setting Pressure kg cm 180 en ene oan Relief Setting Pressure kg ent MN 0 2 0 2 0 2 O 2 o 250 Back Pressure MAX COMET Outward Valve Type CM 150 CM 200 CM 350 CM 450 CM 600 Relief Setting Pressure kg cm 250 Back Pressure MAX 16 18 Since COMET hydraulic breaker operates with various kinds of hydraulic construction machines it should be installed after our serviceman has carried out the necessary check on the base machine to utilize its full performance 4 INSPECTION AND CHARGING OF GAS IN BACK HEAD 1 CHARGING GAS PRESSURE CHANGES ACCORDING TO THE TOOL CONDITION LAY DOWN THE BREAKER AND LET THE TOOL EXTEND FULLY TO CHARGE GAS 2 STAY CLEAR OF THE TOOL WHILE CHARGING THE BREAKER WITH GAS THE TOOL MAY BE IMPACTED BY THE PISTON AND FORCED OUT ABRUPTLY 3 TAKE CARE WHEN THE TIE RODS ARE CHANGED OR THE BREAKER BODY IS DISASSEMBLED 4 USE SPECIAL CARE TO HANDLE AND STOR
13. O ring damage in related parts 1 Replace relevant o ring RELATION OF GAS PRESSURE IMPACT ENERGY AND FREQUENCY ger RC D Gas pressure low Gas pressure 2 GAS LEAKAGE Trouble Remedy Gas leakage from the top Defective o ring in charging valve Replace of charging valve Defective or damaged in charging Repair or replace charging valve valve Gas leakage between Defective o ring in charging valve Replace charging valve and Charging valve loose in back head Re tighten back head Gas leakage between Defective o ring in back head Replace cylinder and back head Gas leakage from drain Defective gas seal in seal retainer Replace plug hole Defective step seal in seal retainer Replace Seizing of piston and seal retainer Repair or replace seal retainer and piston When repaired replace packing 44 3 OIL LEAKAGE Even if oil is leaking there is on use to replacing parts at all times Check the following points listed in the chart below The user can check the marked points before calling the dealer Area of oil leakage Causes amp Remedies A Between the tool and A large amount of oil is leaking Seals damaged lower bush Check if it is coming from oil or Dore REPLACE B Surface of breaker Oil leaking from the hose amp Loose breaker hoses and bolts flange adapter portion RETIGHTEN C Valve housing bolts amp Oil leakage from reassembly NORMAL cap bolts of valve after overhaul
14. Weigh ton 18 25 18 25 18 25 25 30 28 35 28 35 35 48 30 45 40 55 45 60 Specification and features in catalogue are subject to change without prior notice to better improvement in quality 3 Construction and Main Parts Inward Valve Type Tie Rod Back Head Valve Cylinder Accumulator Piston Front Head Tool Tie Rod Front head cylinder and back head of breaker Body are tightly fixed with four tie rods Back Head Oil pressure inlet and outlet ports and Gas charging valve are built in it and the inside is charged with N2 gas Valve Cylindrical control valve is built in the valve housing to control piston reciprocation Cylinder The cylinder is the heart of the breaker containing hydraulic circuit for piston reciprocation Piston Kinetic energy of the piston is converted into blowing energy after hitting the tool The blowing energy is transmitted to the tool to break rocks Front Head The front head supports the whole breaker components upper bushing prevents shock from the tool Tool The specially heat treated tool is directly applied to break rocks It is used as moil point wedge point and flat tool according to the application optional Accumulator The accumulator compensates the pressure in the hydraulic circuit and prevents pulsation It is not usually necessary to refill Use N2 gas only In main body The relation between the area A1 affecting the pressure from th
15. ack of hydraulic oil Hydraulic oil contamination or heat deterioration Poor main pump performance Back head nitrogen gas low Low flow rate by mis adjustment of flow control pressure reduction valve Chisel out of range for blowing position Low accumulator gas pressure of bad accumulator Bad piston or valve sliding surface Piston moves down up to blank blow hammer chamber Tool diameter incorrect Tool and pin jammed from tool retainer pin wear Jammed lower bush and tool Deformed tool and piston contact area Accumulator gas leakage Accumulator diaphragm damage 43 a EM PS F o I ES I p Required action Re adjust nitrogen gas pressure Open stop valve Fill hydraulic oil Tighten or replace Replace back head o ring or cylinder bush step seal Check lines Wash filter or replace Fill hydraulic oil Replace hydraulic oil rinse tank and replace hydraulic oil inside lines Call an authorized service man Refill nitrogen gas Re adjust reduction valve Rush down chisel by excavator operation Refill nitrogen gas Call an authorized service man Rush down tool by excavator operation Replace tool with genuine replacement parts Smoothen rough surface of tool Smoothen rough surface of lower bush interior Replace tool Replace o ring or refill nitrogen gas Replace diaphragm Symptom Required action Oil leakage 1 Cylinder seal worn 1 Replace seal between front head and tool Gas leakage 1
16. base buffer Box Type Change wearing plate Box Type Every 2000 hours or Annually All hydraulic pipe and hose connections Hose interference with excavator boom Conditions of oil filter accumulator diaphragm and through bolts All seals amp Plugs Conditions of piston front cover inner bush Change top buffer amp base buffer 46 12 Moving and lifting Always use eye bolts when lifting amp moving the hydraulic breaker after fasten up to bracket Fasten The ropes to the shackles four pleces and lift the hydraulic breaker up Remove the eye bolts before hydraulic breaker operation The hydraulic system to base machine must be checked by an authorized service engineer before first use and after any modification 13 Storage When operation is interrupted or after operation When operation is interrupted or after finishing the work Move the base on level ground Remove mud from the Hydraulic breaker and set the hydraulic breaker on wood blocks Do not touch the tool when hydraulic breaker just stop to work Because very hot Check whether oil leaks from hydraulic system and whether the tool is damaged f the hydraulic breaker is operated in river Dry the hydraulic breaker body and apply the grease to the front head When hydraulic breaker is not used for a long time 3 weeks more e If the following procedures are neglected the rust is generated in the main body
17. breaker fails to display best performance The old oil is assumed to be contaminated when there is a visual difference between the old and new oil color and functions begin to deteriorate when hydraulic oil turns darker than the new oil color ASTM number by more than two 22 6 Operation breaking 1 PROPER POSITION OF THE TOOL Proper position must be applied for an effective use of breaking force When position is incorrect blowing energy of the piston is too weak to break rocks Instead blowing force applies shocks to the breaker body breaker arm and boom of the base machine thereby resulting in damage to those parts On the contrary when position is excessive enough to break rocks with front of the base machine raised the machine may suddenly tilt forward the moment rocks are broken then the breaker body or the end of bracket may violently hit against rocks and result in damage 23 It is undesirable to carry out hammering under the below condition because vibrations during hammering may be transmitted to tracks of the base machine During hammering however proper position must be always applied to the breaker Special care must be taken not to hammer under abnormal condition 2 ALIGNMENT OF THE TOOL Apply same direction of boom force in line with the tool and place the tool in the rock with hammering surface as vertical as possible If hammering surface is oblique the tool may slip during hammering T
18. e upper chamber of the piston and the A2 affecting the pressure from the lower chamber of the piston is A1 gt A2 and high pressure always applies to A2 When A1 change from high to low pressure or vice versa Piston C2 reciprocates Inside of back head is changed with the high pressure gas and gas energy stored in the up stroke of the C2 effectively acts on the piston C2 during the impact 1 POWER When piston C2 reaches top head center high pressure oil from valve high pressure port B3 applies to upper chamber of the piston A1 to change the piston stroke from upstroke to impact At this time the relation between the area A3 affecting the pressure from valve high pressure changes and the area A4 of the valve change chamber is A4 gt A3 The high pressure always applies to A4 and valve C4 remains in the upper position 2 VALVE SHIFT When cylinder low pressure port B1 is connected to cylinder change port B2 the pressure in valve change port B4 lowers As force acting port C4 is the only pressure in valve high pressure chamber A3 valve C4 starts lowering During the valve lowering stroke valve high pressure port B3 is closed and valve low pressure port B5 is opened to the lower the pressure in the upper chamber of the position A1 3 IMPACT When piston C2 reaches impact point kinetic energy obtained by piston C2 during the impact stroke is transmitted to the tool C3 for the impact energy required to break At this time as
19. eakage and a wide area of rough grey area and final breakage part has the share lip form Such an undulation on the breakage section and its inclination to the right and left can be proved that the breakage is caused by excessive force which exceeds the toughness of the tool Such a breakage is supposed to occur owing to careless handling of the tool To avoid such a breakage more carefulness and attention are required in handling the breaker Stress concentration point al 90 to the tool pin plate Starting point J f o Rough Grey Area lt XS Of Typical fractures caused by levering tool while buried in the burden Warranty claims rejected Typical fractures caused by excessive 75 bending of the tool Warranty claims rejected 45 Le Flat type tool warn more than 45mm or moll type and wedge universal type tools worn back more than 75mm of working end classed as reasionable life Warranty claims rejected sharp lip N A 6 DISASSEMBLEY AND ASSEMBLY OF BREAKER BODY Since breaker body is manufactured by stare of the art processing techniques and consists of high quality hydraulic parts it is dangerous to disassemble breaker at a workshop Contact our service station when disassembly is called for otherwise quality and performance of the breaker cannot be guaranteed 39 9 Wear Tolerance 1 COMET Inward Valve Type e Front Cover Model Inside diameter A Inside diameter as
20. eek Valve Adjuster terming position O turning when fully closed 3 75 4 25 Every Week 2 DAILY BREAKER INSPECTION Before starting operation be sure to inspect the breaker referring to the following table Inspection Item Inspection Point Remedy Looseness missing and Tie rod Check looseness damage to Bracket mounting bolts Retighten securely bolts and nuts Looseness of hose fittings Hydraulic pipes for breaker Retighten securely visible damage to hoses and oil hoses Replace seriously damaged oil leakage parts 36 Inspection Item Inspection Point Remedy Abnormal Connections of back head Consult with COMET oil leakage and cylinder service station for further Clearance between front inspection head amp tool But small leakage is normal from front head Abnormal Tool Deformed burred and worn wear and out tool should be repaired cracks on Excessively worn tool needs tool to be replaced Greasing Grease at start and every 2 Grease front head or 3 hours using head grease pump Pumping 5 10 times Greasing position and method shown at left When greasing press the tool against on the ground See right fig Level and Conditions of hydraulic oil Contamination of hydraulic oil contamination of hydraulic oil caries with operating conditions The oil color tells the level of contamination Criteria for judging contamination is specifically
21. ereafter Replacement of hydraulic oil every 500 hours HYDRAULIC OIL TEMPERATURE AND VISCOSITY Do not operate the hydraulic breaker at oil temperatures from 20 C 68 F to 80 C 176 F Operation at higher temperatures can damage the internal components of the breaker and excavator there will result in reduced breaker performance e Criteria of oil contamination and malfunction General Analysis Analysis Item Causes and Effects when exceeds the criteria Adhesiveness rarely decreases solely because of hydraulic oil Within 10 Entry of different kind of oil may reduce the adhesiveness which 40 C cSt contributes to rising oil temperature wear and stretch of bearings and gears and malfunction of hydraulic oil Adhesiveness Use of a lubricating oil in a long period of time of under high temp of a lubricating higher than 60 C will oxidize it Oxidizing level rises as oxidization proceeds Sludge will be produced during the process Leading to unsatisfactory operation of the breaker erosion of metals or obsolescence of seal materials Less than 0 3 mg KOH g Oxidizing Level Moisture causes rust wear and scratch Moisture of 1 3 gathers a considerable amount of rust And considerable a mount of rust moisture of 0 5 or more will cause damage to the machine Less than 0 1 Moisture e Criteria of malfunction by hydraulic oil color Simple discrimination by ASTM color Hydraulic oil turns black as the
22. hamber C2 goes to chamber V2 A3 area is larger than A4 area but applied pressure of area A3 is the same as applied pressure of A4 Therefore the valve begins to be raised because of the area difference between A4 and A3 Valve Haise 12 4 PISTON DESCENT When the valve reaches the upper limits chamber C4 becomes high pressure area because oil from the working pump goes to chamber C2 through the control valve holes A2 area is larger than A1 area but pressure applied to A4 area is the same as them pressure applied to A1 Therefore the piston begins to be descended because of the area difference between A2 and A1 At this time piston descent speed is accelerated by compressed nitrogen N2 gas pressure and piston weight Piston Descent 5 IMPACT Chamber V2 is changed in low pressure as chamber C2 is connected with C3 during piston descent But V3 is always high pressure Therefore the valve begins to be descended Impact 6 CONTINUOUS STRIKE After the piston strikes the top of the tool the status of all circuits is changed to Piston Raising The piston begins to be raised via status flowing into IN port and the cycle is repeated again 13 5 Preparation for Installation and Operation 1 GENERAL VIEW OF BREAKER INSTALLED nlet piping Stop valve Bracket Pin Bracket 4 Outlet piping Oil cooler Hydraulic tank Hydraulic pump
23. hen reassembling align groove in tool to tool pin hole and insert tool pin e Reverse disassembly procedures to install a replacement tool Before installing a new tool check each part for wear breakage scores etc Remove burrs and swellings on each tool pin apply a coat of grease to the movable and frictional areas of the tool pin and tool and finally install tool Excessively deformed tool pins will make difficult replacement of tool Therefore tool pins are required to be checked every 100 to 150 hours of operation Tool Pin e If replacement tool is not a genuine part we do NOT WARRANTY the performance of other parts of the breaker 38 5 BREAKAGE OF TOOL The service life of various tool depends on the manner of handling them The tool can sufficiently withstand the vertically acting load but it is weak to the perpendicularly acting load Especially the tool is affected by the negative conditions such as force by craning operation tilted blowing wrenching idle strokes etc its service life become shorter There are several ways of breakage of tool Each cause of breakage can be inferred by observing breakage sections Further the breakage case which is not caused by low quality materials or insufficient heat treatment but by wrong way of handling which the manufacturer is not responsible for the breakage See below figure The breakage section has the origin on the outer surface a narrow area of fatigue br
24. her there is a surplus of the tool when the breaker is lifted e Avoid all blank hammering As soon as rocks are broken stop hammering Continuous blank hammering will not only damage front head and loosen and break bolts but also adversely affect base machine Blank hammering occurs when proper position of the tool is not applied to the breaker or the tool is used as a lever Hammering sound changes during blank hammering e Do not move rocks Avoid moving rocks with side of the bracket because it is the major factor to break bolts installed on the bracket tool and damage boom and arm 26 Do notuse tool as a lever When breaking rocks by using tool as a lever bolts and tool may be broken too e Do not continue to hammer for more than one minute When rocks are not broken after more than one minute s hammering at the same point change the place to be hammed Extended hammering at the same place causes the tool to wear out excessively e On a hard and large rock start breaking at start breaking from the edge Even a hard and big rock can be easily broken when hammering begins at a crack or an edge Operate breaker at proper engine speed Break rocks at the specified engine speed Raising engine speed more than necessary does not strengthen hammering force but increase oil temperature to the detriment of pistons and valves Hydraulic breaker operation jie set the center to arrow
25. high pressure applies only to the lower chamber of the piston A2 piston C2 starts reversing Further as high pressure applies only to the valve high pressure chamber A3 valve C4 is remaining in the lower position 4 UPSTROKE When cylinder change port B2 is connected to cylinder lower pressure port B1 high pressure oil applies to low pressure outlet port valve C4 time valve low pressure port A1 this time valve low pressure port B5 is closed and valve high pressure B3 is opened the upper chamber of the piston A1 to rise the pressure in the lower chamber of the piston A1 Area of the upper chamber of the piston Area of the lower chamber of the piston Area of valve high pressure chamber Area of valve change chamber Cylinder low pressure port Cylinder change port Valve high pressure port 10 Valve change port Power cell Valve low pressure port Piston Tool Valve 4 Construction and Main Parts Outward Valve Type IT TT Tie Rod Back head Gas Chamber Cylinder Control valve Eee AU i Accumulator Piston Front head Tool retainer Tool 11 Tie Rod Front head cylinder and back head of breaker body are tightly fixed with four tie rods Back Head Gas charging valve is built in and the inside is changed with N2 gas Cylinder The cylinder is the heart of the breaker containing
26. his causes the tool to seize and to be broken and piston to be damaged When breaking fully stabilize the tool first and then select the point of a rock on which hammering can be performed in a stable condition 24 3 OPERATION PRECAUTIONS IMPORTANT APPLY DOWN FORCE TO THE BOOM DIPPER UNTIL THE FRONT OF THE BACKHOE AND CARRIER IS ARISED OFF THE GROUND THE BREAKER IS MORE EFFICIENT WHEN ADEQUATE DOWN FORCE IS APPLIED IMPORTANT RELOCATE THE BREAKER OFTEN THE BREAKER TOOL SHOULD BE MOVED TO A NEW LOCATION OF THE WORK EACH TIME THE TOOL PENETRATES BUT DOSE NOT CRACK THE MATERIAL IMPORTANT DO NOT BREAK CONTINOUSLY IN ONE PLACE CONTINUOUS PENETRATION IN THE SAME AREA FOR LENGTHILY PERIODS WILL CREATE EXCESSIVE TEMPERATURES AT THE END OF TOOL RESULTING IN LOSS OF TEMPER HARDNESS OF THE BIT AND CAUSING MUSHROOMING OF THE TIP OF THE BIT AND MAY LEAD TO FAILURE OF THE BIT IMPORTANT DO NOT PRY WITH THE BIT AND BREAKER IMPORTANT e THE CONTAMINAED PART MUST BE CLEANED WITH NO DELAY HYDRAULIC OIL OR LIGHT OIL IS HIGHLY RECOMMENDED 25 Stop operation as soon as hose vibrate excessively Excessive vibration of high and low pressure hoses of breaker calls for an instant disassembly and repair Contact the nearest service station appointed by Comet For caution s sake check oil leakage at back head The operator is required to pay attention to following points during operation Visually inspect whet
27. hydraulic circuit for piston reciprocation Control Valve Cylindrical control valve is built in the valve housing to control piston reciprocation Accumulator The accumulator compensates the pressure in the hydraulic circuit and prevents pulsation It is not usually necessary to refill Use N2 gas only Front Head The front head supports the whole breaker components Upper bushing prevents shock from the tool Tool The specially heat treated tool is directly applied to break rocks It has various forms of a wedge moil point blunt cone and wedge chisel appropriate to the application optional 1 SET UP Chambers C3 C2 always maintain low pressure because they are connected to the output line Chambers V3 V1 C1 and accumulator always maintain high pressure because they are connected to the input line Chamber V2 pressure is changed to low pressure or high pressure depending on piston position 2 PISTON RAISE V3 Accumulator Piston Raise Oil enters into IN port and begins to accumulate force to raise piston hydraulic force is applied on A1 of piston lower flange and piston begins to be raised When the piston begins to be raised oil from C4 chamber returns to the output line through the control valve 3 VALVE RAISE When piston be raised to around upper limits A1 of piston lower flange reaches chamber C2 and the back head nitrogen N2 gas is compressed At this time oil from c
28. ion COMET Breaker Description kg 102 127 166 205 290 433 553 860 1350 1863 BOX TYPE Ib 225 280 366 452 639 954 1219 1896 2976 4107 Operating Weight kg 70 100 160 195 260 410 510 820 1310 1862 Mount C TOP TYPE as 8 Ib 154 220 353 430 573 904 1124 1808 2888 4105 kg 70 100 140 180 250 340 395 473 765 1310 1862 SIDE TYPE Ib 154 220 309 396 551 749 870 1043 1685 2888 3373 kg 51 61 76 116 136 136 190 240 414 498 833 Weight of Main Body Ib 112 134 168 226 300 300 419 529 913 1098 1836 l min 15 30 20 40 20 50 30 60 30 50 30 50 50 90 45 90 80 110 90 120 130 150 Required Oil Folw gal min 4 8 5 10 5 13 8 16 8 16 8 16 16 24 12 24 21 29 24 32 34 40 bar 130 140 150 150 160 160 180 180 210 210 210 Setting pressure psi 1885 2030 2175 2175 2320 2320 2611 2611 3046 3046 3046 bar 90 120 90 120 100 130 100 130 90 130 90 130 120 150 130 150 150 170 150 170 160 180 Operating pressure psi 1305 1740 1305 1740 1305 1740 1450 1885 1305 1885 1305 1885 1740 2176 1885 2176 2176 2465 2176 2465 2321 2611 Impact Rate bpm 800 1400 700 1100 550 950 500 1000 450 750 450 750 400 800 400 800 450 630 400 750 400 800 mm 13 13 13 13 13 13 13 18 18 25 25 Hose Diameter inch 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 3 4 1 1 Tool Diameter mm 40 45 53 60 68 68 75 85 100 120 135 Tool Length mm 400 500 580 600 690 690 750 800 1000 1100 1200 Applicable carrier Weigh ton 0 5 1 5 0 8 3 1 5 4 3 5 5 4 6
29. is time and put into a container e Be careful to prevent mud or dust from entering oil hoses and pipe lines Plug oil hoses with hose plug and pipe lines with union caps Bind high and low pressure hoses with a wire to prevent them from getting mud 30 e To remove the breaker pull out pins in the bucket link and arm When leaving the breaker outdoor set the breaker on wood blocks and cover with sheets e When leaving the breaker removed for a long period of time Clean exterior of the breaker Remove tool from the front head and spray with rust preventive oil Bleed N2 gas from the back head before pushing piston into cylinder Apply grease to each part of the breaker and then install tool again e To install the hydraulic breaker reverse the fore mentioned removal procedures The bucket operation easily contaminates the end part of hoses and pipe lines The contaminated part must be cleaned with no delay Hydraulic oil is highly recommendable Never insert your hand or fingers into the pin hole WARINING While aligning the arm hole or moving the bucket make sure that there are no person In the vicinity of arm or bucket of base machine e itis dangerous to move the base machine suddenly during installation Wear the safety shoes to protect feet NOTICE Be careful so that dust may not enter the hydraulic breaker and base machine Install or remove the hydraulic breaker on hor
30. izontal ground without mud or dust 1 Set the hydraulic breaker on horizontal ground 2 Remove the bucket from the base machine after disassembling the two pins NOTICE e if the bucket cylinder is retracted the installation will be easier 3 Move the base machine in the vicinity of hydraulic breaker and align the pin hole of arm with the pin hole of hydraulic breaker and then insert the pins 4 After the arm pin is inserted lift the boom resert the hydraulic breaker on the wood blocks like as Extend the bucket cylinder fit it to the bucket link s hole and insert the pins 5 Install the stop rings align the bolt holes and insert the bolts Mutually lock double nut NOTICE e if the stop rings are secured with one nut only the service life of the bolt may be shortened or the bolt may be loosened our very quickly 6 Stop the engine of the base machine tun off the main switch and discharge the air pressure in the hydraulic oil tank 7 Remove the union caps from the hydraulic breaker pipe of the arm end and connect the hoses after disassembling the hose plug NOTICE Do not allow the oil to drop onto the ground Store the removed union cap and hose plug in the tool box When installing or removing the oil hose and union cap clean them fully to prevent the dust and mud from entering the hydraulic breaker or the base machine 32 Personal Injury ca
31. n operating the breaker you must use ear and body protection You must use ear and breathing protection when the breaker is operating e Accumulator type danger Attention to pressurized container Do not open without reading the manual or consulting with the authorized service personal e Greasing With breaker mounted on carrier Apply down pressure on tool and fill cavity with recommended grease through the grease nipple e Always wear eye protection when Stop pin is being removed it in and out with a punch and hammer 29 Installation and Removal of the Hydraulic Breaker When the bucket and breaker operation are performed alternately the bucket and breaker can be easily exchanged by the hydraulic hoses and two pins There is however a risk of the hydraulic circuit contamination Accordingly install and remove as follows Move the base machine to stable ground free from mud dust and dirt Stop the Wood block engine turn off the main switch and on Position of the base machine for installation deflate air from oil tank if it is pressurized and removal of the hydraulic breaker Turn 90 the stop valve installed to the end of arm to prevent hydraulic form flowing out Stop valve Fitting Oil hose E Lp T Warning As Tool may ily out due to N2 gas pressure do not approach to the tool Loosen hose plug on the breaker arm Collect small amount of oil flowing out at th
32. n result from dropping pins during removal Wear safety shoes to protect feet 1 Setthe hydraulic breaker on clean and horizontal ground Lock the packing brake of base machine 2 Stop the engine 3 Turn stop valve to OFF position 4 Disconnect hoses from stop valves Ensure no leakage occurs from hoses and stop valves 5 Apply union cap and plug to hose ends fittings to prevent 6 Remove pins fixing fasteners 7 Remove pins 8 When pins have been withdrawn move operating joystick slightly to take weight off remaining link pin 9 Lift arm away from hydraulic breaker so that hydraulic breaker can be carried away or another attachment mounted on base machine NOTICE Cover the hydraulic breaker already removed with sheet and then store it in doors 33 8 Repair and Inspection 1 INSPECTION POINTS COMET Inward Valve Type Tie Rod Fixing Torque A Side Bolt Fixing View K Torque D Accumulator Accumulator x Plug Cap Torque Torque B Greasing i Before start and every 2 or 3 Socket Bolt Fixing hours of operation Torque H 34 COMET Inward Valve Type Tie rod fixing torque Accumulator fixing torque Accumulator plug fixing torque Side bolt fixing torque Socket bolt fixing torque Back head gas pressure at 20 C 68 F Accumulator N gas pressure at 20 C 68 F Valve Adjuster terming po
33. new part mm as reject limit mm CM 10 40 42 CM 20 45 47 CM 30 55 CM 35 60 5 63 5 CM 40 40BL 68 71 CM 55 79 CM 70 85 89 CM 100 105 CM 220 135 140 250 140 145 330 155 CM 400 160 measure at center CM 500 170 CM 550 180 SA measure al 10mm e Thrust Bush Inside diameter as reject limit mm CM 20 45 47 CM 30 55 CM 35 62 5 CM 40 40BL 68 71 CM 55 75 79 CM 70 89 CM 100 105 CM 220 140 CM 250 140 145 CM 330 155 CM 400 160 measure at 30mm CM 500 170 CM 550 180 e Tool Pin Model as new part mm as reject limit mm CM 10 18 CM 20 22 CM 30 22 CM 35 34 CM 40 40BL 28 CM 55 28 CM 70 51 CM 100 57 CM 220 80 77 CM 250 xC 8 86 CM 330 90 5 A CM 400 94 pie CM 500 94 CM 550 96 5 40 Model Outside diameter Outside diameter B Outside diameter Outside diameter B ode as new prat mm as reject limit mm as new prat mm as reject limit mm 10 8 CM 10 CM 20 10 8 CM 30 10 8 CM220 20 18 CM 35 13 11 CM250 20 18 CM 55 CM400 17 5 15 5 Front Cover Pin Model Outside diameter Outside diameter B Outside diameter Outside diameter B ode as new prat mm as reject limit mm as new prat mm as reject limit mm CM 10 13 11 CM 30 13 CM220 30 28 Tool Effective lengh Usable length B Outside diamete A Outside diameter B 2 COMET Outward Valve Type Front Cover Model Inside diameter A Inside diameter ode as new part mm a
34. nfluence of drugs or alcohol Remove breaker from carrier during the transport e Warning sticker shown smaller then actual size Use Hearing Protection Use Eye Protection Use Breathing Protection Read the manual before use Safety symbols DANGER WARNING IMPORATNT This safety symbol may appear on the This safety symbol appears in these This safety symbol appears in these breaker It is used to alert the operator of instructions to identify an action that instructions to identify an action or an action that could place him her or could cause bodily injury to the condition that could result in damage other in a life threatening situation operator or other personnel to the breaker or other equipment Safety symbols are to emphasize all operator maintenance and repair action which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment Always observe safety symbols They are symbols for your safety and for the protection of the tool Greasing sticker GREASING GREASING 1 With breaker mounted on carrier apply down pressure on tool 2 Fill cavity with recommended grease 3 Grease whenever tool looks dry 4 When installing a new tool liberally coat the upper 1 3 of the tool with grease before inserting 5 Failure to comply with these instruction can result in damage To the breaker and will void the warranty 2 Technical Specificat
35. s reject limit mm CM 150 120 126 CM 400 155 163 CM 450 160 168 Measure at the 10mm position CM 600 180 188 __ from the and face Thrust Bush Model Inside diameter A Inside diameter as new part mm as reject limit mm CM 200 135 ST CM 350 158 CM 400 155 measure at JOmen Tool Pin m as reject imit mm CM 150 67 CM 200 77 350 89 86 400 100 97 450 97 600 117 Stop Pin Model Outside diameter B as new part mm as reject limit mm CM 150 17 5 15 5 CM 200 18 CM 350 18 CM 400 23 CM 450 23 CM 600 24 Front Cover Pin as new part mm as reject limit mm CM 150 24 CM 200 28 CM 350 28 CM 400 34 CM 450 34 CM 600 34 Tool as new part mm as reject limit mm CM 150 380 CM 200 450 CM 350 780 460 CM 400 480 CM 450 480 CM 600 914 485 42 10 Trouble shooting guide 1 PROBLEMS IN OPERATION If the breaker does not work or blow frequency and blow power get worse check the arranging method And then inspect according to the following order Symptom No blow out Low impact power Irregular impact Bad tool movement Sudden reduction power and pressure line vibration Cause Excessive back head gas pressure Stop valve s closed Lack of hydraulic oil Wrong adjustment of pressure reducing valve Faulty hydraulic hose connection Oil back head infection Line leakage or blockage Clogged tank return line filter L
36. sition Make sure all control levers and pedals are in the neutral position before starting the carrier Before leaving the carrier always lower the boom and insure the carrier is stable Never leave the machine when the engine is running Always engage the parking breaker locked Stop the engine before attempting to make any repairs adjustments or servicing to either the carrier or the breaker Do not operate the breaker at oil temperature above 175 F 80 C Operation at higher temperatures can damage the internal components of the breaker and as well as backhoe excavator and will result in low breaker performance Do not operate the breaker at in the severe conditions such as a damage leaking improperly adjusted or incompletely assembled breaker Do not modify breaker tool in any manner Use only breaker and breaker tools manufactured by Comet only Using the breaker tool produced by other manufacturers may damage the equipment and will void the warranty To avoid personal injury or equipment damage all breaker repair maintenance and service must only be performed by authorized and properly trained personnel If you do not understand how to operate your breaker contact an authorized Comet Dealer for assistance Keep this manual with the breaker Do not operate this equipment if you are taking medication which may affect you mental judgment or physical performance Do not operate this equipment if you are under the i
37. sition O tuming when fully closed Unit CM10 CM20 CM30 CM35 15 e COMET Outward Valve Type Valve adjuster direction Back head N2 gas Pressure F Valve adjuster Turning position H Accumulator N2 gas Pressure G Greasing Before start and every 2 or 3 hours of operation Max 100cc 39 CM55 CM70 CM100 CM220 CM250 CM330 CM400 CM500 CM550 BOBBEBEREBEEBBEBE LI T E rr CPL ET ET 16 5 psi 213 213 235 235 235 235 235 235 235 235 235 235 235 235 j LLL 767 767 767 824 782 782 782 896 DEBDEBSIBEENEEBB nin uH uH bil mE o Tie rod fixing Torque A Accumulator charging plug Fixing torque C Accumulator Socket bolt Fixing torque D Side bolt Fixing torque E COMET Outward Valve Type Part CM150 CM200 CM350 CM450 cm goo mspection interval Tie rodfixing torque DE 150 170 240 250 270 370 270 330 350 400 Every Week Accumulator fixing torque 60 65 50 65 60 65 60 65 60 65 Every Week Accumulator plug fixing torque C E 8 12 x 8 12 x 8 12 x 8 12 x 8 12 Every Week Socket bolt fixing torque ma 20 25 30 40 30 40 40 45 40 50 Every Week Side bolt fixing torque 200 220 250 270 250 270 320 350 320 400 Every Week 2 at 20 C 68 F Every Week Kg cm 54 55 54 55 54 55 58 63 58 63 Every Week Accumulator gas pressure at 20 C 68 F 767 782 167 782 167 782 824 896 824 896 Every W
38. to cause serious Troubles Discharge the nitrogen gas with the back head and accumulator and then push the piston to avoid rust into the cylinder Assemble the tool and store the hydraulic breaker indoors after applying the grease to every part especially Internal part of front head 47
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