GH40 Service Part A
Contents
1. Fig 14 6 Adjust hydraulic motor spacer for even fit Fig 14 5 Lower hydraulic motor onto gear drive box DO NOT OPERATE THIS MACHINE W THE CHAIN COVER PLATE REMOVED Fig 14 7 Apply sealant to the socket Fig 14 8 Securely tighten socket head head cap screws cap screws Service Manual Rotation Member Page 50 Geoprobe GH 40 Hammer Fig 14 9 Position 12 tooth sprocket on hydraulic Fig 14 10 Measure chain height beside 12 tooth motor shaft sprocket Fig 14 11 Measure chain height near bottom plate of rotation member Fig 14 13 Apply sealant to chain cover plate mating Fig 14 14 Attach chain cover plate to gear drive surface box Service Manual Rotation Member Page 51 Geoprobe GH 40 Hammer Fig 14 17 Hydraulic motor installation is complete Service Manual Rotation Member Page 52 Fig 14 16 Secure hammer rotation valve to hy draulic motor Geoprobe GH 40 Hammer 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 15 10 15 11 15 12 15 13 15 14 15 15 15 16 15 0 DRIVE CHAIN AND 12 5 REMOVAL Extend foot approximately 2 feet from the rear of the vehicle using Probe Control lever and move hammer towards the front of the vehicle approximately 6 to 8 inches Fig 15 1 Do not move the hammer too far forward The probe cylinder may d2. Lit hire 14141474 i le Fig 16 1 Cut new section of 50 drive chain with Fig 16 2 New drive chain should measure chain detacher 21 inches or 17 links Service Manual Rotation Member Page 57 Geoprobe GH 40 Hammer Fig 16 3 Attach new offset link to drive chain Fig 16 4 Coil chain to fit into gear drive box Fig 16 5 Feed end of drive chain into and around hex drive gear using a drill steel Fig 16 7 Connect loose ends of chain with connec tor link and link keeper Service Manual Rotation Member Page 58 Fig 16 6 Leading edge of chain should reach hydraulic motor shaft slot Fig 16 8 Place 12 tooth sprocket in chain under hydraulic motor shaft slot Geoprobe GH 40 Hammer 17 0 HEX DRIVE GEAR BEARINGS AND SEALS REMOVAL NOTE Internal parts in this section are pictured free of grease Normally internal parts will be coated with grease This section describes the process required to remove the innermost working parts of the rotation member of the Geoprobe GH 40 hammer The parts described include the hex drive assembly two roller bearings and two grease seals Most disassembly of the rotation member will occur on the work bench in order to centralize the work area For the removal of the hydraulic motor drive chain and 12 tooth sprocket the technician is referred to previous sections which describe the
3. 14 2 Place hydraulic motor spacer on gear drive box and align bolt holes Fig 14 2 14 3 Align the half moon key in hydraulic motor shaft with the key way in the 12 tooth sprocket Fig 14 3 Turn hex drive manually or with a 1 hex tool to achieve this alignment Fig 14 4 Assistance may be required to hold the 12 tooth sprocket in the drive chain 144 Lower the hydraulic motor onto the gear drive box Fig 14 5 Care must be taken to support the 12 tooth sprocket and drive chain during this process 145 Adjust the hydraulic motor spacer for an even fit at the hydraulic motor base Fig 14 6 14 6 Apply Hercules Real Tuff Teflon Paste Thread Sealant or its equivalent on both socket head cap screws which secure the hydraulic motor to the drive gear box Fig 14 7 14 7 Securely tighten socket head cap screws using a 3 8 hex bit and socket wrench or allen wrench Fig 14 8 148 Using a small crow bar and manual pressure position 12 tooth sprocket on hydraulic motor shaft so distance between the chain and the top of the gear drive box is approximately the same at all locations Fig 14 9 14 9 Measure chain height withacaliperto achieve proper sprocket location by taking two measurements one beside 12 tooth sprocket Fig 14 10 and one as close as possible to bottom plate of rotation member Fig 14 11 14 10 Tighten the 12 tooth sprocket set screws with a 1 8 or 5 32 allen wrench Fig 14 12 14 11 Apply a thin film of P
4. CAUTION Do not scratch valve spool while removing it from valve body or when removing O rings 11 15 Pull valve spool out of the valve body Fig 11 11 Service Manual Rotation Member Page 34 Geoprobe GH 40 Hammer 11 16 If necessary remove screw and lock washer securing the hammer valve handle to valve spool and remove handle Fig 11 12 11 17 Remove remaining retainer ring Fig 11 13 11 18 Remove the two O rings from their grooves in the valve spool using a pick or small screwdriver Fig 11 14 11 19 Wash all hammer rotation valve parts in solvent and blow dry with compressed air 11 20 Inspect all parts for excessive wear Fig 11 2 Move hydraulic levers on control panel to relieve pressure in lines Fig 11 1 Position the GH 40 hammer for service Service Manual Rotation Member Page 35 Geoprobe GH 40 Hammer Fig 11 3 Identify and tag hydraulic hoses going into valve body Fig 11 4 Disconnect hydraulic fittings Fig 11 5A Cover hoses with small plastic bags Option 1 ae Fig 11 5B Plug hose ends with 8 MJ hydraulic fitting plugs Option 2 H 4 Fig 11 6 Remove socket head cap screws Service Manual Rotation Member Page 36 Geoprobe GH 40 Hammer Fig 11 8 Remove O rings in hydraulic motor ports Fig 11 7 Pull valve away from hydraulic
5. 13 8 13 9 to do so will severely damage the hydraulic system Fully extend unit from vehicle Adjust derrick with Fold Control so derrick is approximately at a 60 degree angle relative to the ground Lower probe foot approximately 1 5 to 2 feet Raise the rotation member with the Probe Control to approximately chest high Fig 13 1 Deactivate hydraulics and shut off vehicle engine Remove the two chain cover bolts and lock washers using 9 16 wrench Fig 13 2 Remove chain cover plate Fig 13 3 Loosen set screws at the base of the 12 tooth sprocket with 1 8 or 5 32 allen wrench Fig 13 4 Remove the four socket head cap screws securing the hammer rotation valve to the hydraulic motor Fig 13 5 using 1 4 hex bit and socket wrench NOTE Early model GH 40 rotation members utilize lock washers in securing the valve body to the 13 10 13 11 13 12 13 13 13 14 13 15 13 16 13 17 hydraulic motor Pull the hammer rotation valve straight away from the hydraulic motor Fig 13 6 Plug ports on hammer rotation valve with 1 2 plastic plugs or place the valve in a plastic bag and secure with a rubber band Fig 13 7 Remove the two O rings from the hydraulic motor one from each port from their respective grooves and place in a safe location Fig 13 8 Plug hydraulic motor oil ports with plastic plugs Fig 13 9 If the derrick has been placed at the proper angle the rotation valve will automatic
6. 1 1 GH 40 HAMMER MAJOR COMPONENTS Service Manual Page 6 Geoprobe GH 40 Hammer 3 0 SERVICING THE 40 MEMBER 3 1 When is service necessary When the hammer seizes fails to deliver percussion When oil leaks from vents at the front or rear of the base plate or out of the top vent When hydraulic oil in excess leaks down around anvil 3 2 What servicing can be done in the field The only service which should be undertaken in the field is the removal and replacement of the lower hammer seals which are located in the base plate of the hammer assembly 3 3 What servicing must be done at the factory The hammer member should be sent to the factory for any repairs above the base plate These repairs may include recharging the hammer with nitrogen replacing the top piston seal replacing the accumulator diaphram etc NOTE Certified technicians with access to the proper equipment may recharge the hammer member with nitrogen following the instructions in Section 7 0 Recharging Hammer With Nitrogen 3 4 What tools are required to service the hammer member portion of the GH 40 Hammer ITEM QUANTITY Socket Wrench 1 2 drive 1 Torque Wrench 1 2 drive Socket 15 16 and 3 4 Open Ended Wrench 7 8 and 15 16 Dead Blow Hammer brass or plastic hammer head Small Pick an ice pick or small screw driver will do 8 MJ Hydraulic Fitting Caps Optional 8 MJ Hydraulic Fitting Plugs Optional Small Pry Bar Oil Can
7. 4B Plug ends all hydraulic lines with Fig 4 5 Cap hammer inlet and return openings 8 MJ plugs Option 2 after hoses have been removed b s ROO NUTS 1 eoprobe GH 40 Fig 4 6A Loosen base plate bolt which secures Fig 4 6B Remove hammer base plate bolts hammer member to rotation member Service Manual Hammer Member Page 10 Geoprobe GH 40 Hammer l Fig 4 7 Remove top mounting bracket Fig 4 8 Loosen hammer member from bolt lower rotation member Fig 4 9 Remove hammer member Fig 4 10 Removal of hammer member is complete Service Manual Hammer Member Page 11 Geoprobe GH 40 Hammer 5 0 REMOVAL MEMBER BASE SEALS The hammer member base plate seals may need to be replaced if hydraulic oil is leaking from the vent holes or around the anvil NOTE An exploded view of the hammer member base plate seals is shown in Fig 5 1 5 1 5 2 5 3 Clamp hammer member in a bench vice Fig 5 2 Vice jaws should contact hammer between the recessions on both sides of the accumulator housing To prevent marring a shop rag should be wrapped around the accumulator housing before clamping it in the vice Remove side rod nuts with a 15 16 socket wrench Fig 5 3 Remove base plate by tapping base plate flange with a dead blow hammer Fig 5 4 Be sure to check orientation of base plate to hammer body A
8. 7 4 Nitrogen charge valve and lock port nut Service Manual Hammer Member Page 21 Geoprobe GH 40 Hammer Fig 7 5 Loosen lock nut on nitrogen charge Fig 7 6 Thread hex cap of charge valve adapter valve one full revolution into nitrogen charge port until hand tight Fig 7 7 Thread charge valve adapter center Fig 7 8 Attach nitrogen fill hose to charge valve seam into hex cap until stem is hand tight adapter at quick connects Fig 7 9 Nitrogen gas regulator tee handle Fig 7 10 Nitrogen gas cylinder main valve Service Manual Hammer Member Page 22 Geoprobe GH 40 Hammer Fig 7 11 Unthread the charge valve adapter center stem out from the hex cap Fig 7 12 Check for dripping oil around base plate and piston Fig 7 13 Check for dripping oil from hex drive Service Manual Hammer Member Page 23 Geoprobe GH 40 Hammer 80 MEMBER INSTALLATION CAUTION Upper hammer member is heavy Do not attempt to install it on your own Seek assistance when installing it in mounting brackets and rotation member NOTE Refer to Section 24 0 or 26 0 for instructions on reinstalling the Hammer Brace Assembly or 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 Rod Grip Pull Assembly if this accessory has been installed on your GH 40 Hammer With assistance place hammer member onto the rotation member so that hammer alignment pins in the rotation member fit into th
9. for an H wiper E r FLOW SLEEVE TUBE SEAL WASHER CUP SEAL A N WIPER No AN H WIPER BASE PLATE O RING Ju SIDE ROD NUTS 4 e FIGURE 5 1 GH 40 HAMMER MEMBER SEAL REPLACEMENT Service Manual Hammer Member Page 13 Geoprobe GH 40 Hammer Fig 5 2 hammer member in vise Fig 5 3 Remove side rod nuts Fig 5 4 Remove base plate Fig 5 5 Top view of base plate showing cup seal top seal washer center and D or wiper bottom Service Manual Hammer Member Page 14 Geoprobe GH 40 Hammer Fig 5 6 seal Fig 5 7 Remove seal washer D or H wiper Fig 5 8 Remove base plate O ring Service Manual Hammer Member Page 15 Geoprobe GH 40 Hammer 6 0 INSTALLATION OF BASE SEALS NOTE The Geoprobe Replacement Seal Kit GH 4120K contains a new cup seal seal washer D wiper H wiper and O ring This kit is required to complete the following procedure Only one of the wipers will be used during the seal replacement process NOTE Recenthammer improvements have replaced the D wiper with an H wiper Determination of the correct wiper to be used can be made as follows the wiper s physical appearance resembles that of the cup seal and requires a chamfered base plate to accommodate its lower sealing surface Be sure to determine which wiper
10. the gear drive box will not readily separate tap the exposed edge ofthe box with a dead blow hammerto jaritloose Then manually work the gear drive box free Lift the gear drive box off the bottom plate Fig 17 15 Pull the hex drive gear out of the bottom plate Fig 17 16 The top and bottom tapered roller bearings should remain attached to the upper and lower stems of the hex drive Remove bearings from the hex drive by hand Fig 17 17 If this fails use a chisel or bearing puller to loosen bearings If the bearings are to be reused take care not to damage them during removal Remove top and bottom grease seals from the top and bottom plates using a seal remover or hammer and punch Fig 17 18 NOTE The use of a bench vise may aid in the removal of the alignment pin and bearing race 17 23 17 24 17 25 17 26 In order to ease the bearing race removal process from the top plate the hammer alignment pins should be removed from the top plate with a large pair of vice grips Fig 17 19 Insert a dowel pin or punch through hammer alignment pin holes and hammer bearing race out of top plate Fig 17 20 The bottom bearing race will be more difficult to remove Hammer race out of bottom plate by angling a small drift punch or chisel through the hex drive hole in the bottom plate to the exposed shoulder of the bearing race Fig 17 21 The most effective hammering technique is to hammer downward at an angle Turn the bottom
11. them on the sharp edges of valve spool Fig 10 9 10 14 Lubricate new No 116 O rings and valve spool with a coat of oil or grease Fig 10 10 CAUTION lack of lubrication on the O rings or simply pushing the valve spool straight into the valve body may damage the O rings 10 15 With a slight back and forth rotation gently push the valve spool into the valve body Fig 10 11 10 16 The rotation valve lever should be placed in its original position between the rotation valve stop pins between the 9 o clock and 12 o clock position as viewed from the passenger side ofthe vehicle Fig 10 12 10 17 Clean valve body around the area where the valve spool was installed Fig 10 13 Service Manual Rotation Member Page 29 Geoprobe GH 40 Hammer 10 18 Install the retainer ring on the spool between the hydraulic motor and the valve body Fig 10 14 Start one end of the ring in the groove and gently work it around the spool with a flat blade screwdriver 10 19 Pull out gently on valve spool handle to ensure proper engagement of valve spool retainer ring 10 20 Start unit and check for proper operation of the hammer and rotary unit Fig 10 2 Move hydraulic levers on control panel to relieve pressure in lines Fig 10 1 Position the GH 40 Hammer Fig 10 3 Remove retainer ring Service Manual Rotation Member Page 30 Geoprobe GH 40 Hammer Fig 10 4 Clean around spool area where retainer rin
12. 0 Section 18 0 Section 19 0 Section 20 0 Section 21 0 Section 22 0 Section 23 0 Section 24 0 Section 25 0 Section 26 0 Section 27 0 Section 28 0 Service Manual TABLE OF CONTENTS Introduction o k i ea WR Re Hek SS 5 Saf tyPE CaW LIO H Si PPS 5 Figure 1 1 GH 40 Hammer Major Components reree 6 Servicing the GH 40 Hammer Member 7 Hammer Member Removal esoronnoenvennrennennssnnenneennenneennennnennneneenneennenneennenneennennsnenee 8 Removal of Hammer Member Base Plate Seals eee 12 Figure 5 1 GH 40 Hammer Member Seal Replacemen 13 Installation of Base Plate Seals eee eese esee eene entente 16 Recharging Nitrogen in GH 40 Hammer 20 Hammer Member Installation eere eee eese eee eene nete tense tn tenant tns ttnsun 28 Servicing the Rotation Member esee eese eese eene entente aetas estas ens tn sn 3l Figure 9 1 GH 40 Rotation Member Service Diagram 32 Valve Spool O Ring 33 Hammer Rotation Valve Removal and Disassembliyi 38 Hammer Rotation Valv
13. GEOPROBE GH40 HYDRAULIC HAMMER SERVICE MANUAL Technical Bulletin No 95 040 PREPARED February 1995 REVISED April 2002 GEOPROBE GH40 HYDRAULIC HAMMER Geoprobe Systems A DIVISION OF KEJR INC COPYRIGHTO 2002 2000 1995 Kejr Inc ALL RIGHTS RESERVED No part of this publication may be reproducedor transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from Kejr Inc WARRANTY Geoprobe Systems warrants its products to be free from defects in materials and workmanship under normal use and service for period of one hundred eighty 180 days from the date of delivery to the client Geoprobe Systems will repair or replace any product returned to Salina Kansas which appears upon inspection by Geoprobe Systems to be defective in materials or workmanship Geoprobe Systems shall have no obligation under this warranty for the cost of labor down time transportation charges or for repair or replacement of any product which has been misused carelessly handled or modified or altered All other warranties of every kind whether expressed or implied including but not limited to any implied warranty of merchantability or of fitness for a particular purpose and all claims for consequential damages are specifically disclaimed and excluded Geoprobe Systems is a Division of Kejr Inc located at 601 Nort
14. Hydraulic Fitting Plugs Optional 2 Small Pick An ice pick or small screw driver will do 1 Small Crow Bar 1 5 to 2 feet in length 1 U S Tsubaki No D 35 Chain Detacher or equivalent 1 Permatex Aviation Forma Gasket or equivalent Hercules Real Tuff Teflon Paste Thread Sealant or equivalent Service Manual Rotation Member Page 27 Geoprobe GH 40 Hammer Service Manual Rotation Member FIGURE 9 1 GH 40 ROTATION MEMBER SERVICE DIAGRAM Page 28 GH 40 HAMMER MATERIAL LIST NO Qty Pt No 1254 1127 1255 1256 512575 1126 1073 1129 1263 1258 1077 1076 21121 1259 1260 1128 1095 Se 1107 1096 1108 1105 1264 1261 1262 1265 1266 1267 1268 1269 9446 1271 1272 1278 1274 sz 1275 1276 5 9730 1249 121919 1821 1322 9045 9047 Fey a l e V 4478 6863 AT225 1223 8600 4582 5820 3309 8307 3308 8605 Shim Gearbox 0 01 LARA A A pbb N2 N NN DA 2 2 AM A 2 A A A A 2 2 2 N2 2 2 DN Description Pin Spg 0 25 x 1 Plate Top RB TPR 4 375 OD RB TPR Cone 2in Bore Pin Dowel 0 25 x 2 25 Plate Middle Spr
15. Shooting 97 Referen OS RUN 99 Page 4 Geoprobe GH 40 Hammer 1 1 1 2 1 3 1 4 1 5 2 1 2 2 2 3 2 4 2 5 2 6 2 7 1 0 INTRODUCTION Purpose This manual provides step by step instructions for servicing the Geoprobe GH 40 hydraulic hammer Introduction to the GH 40 Hammer The GH 40 Hydraulic Hammer is divided into two distinct parts for purposes of service Those parts are the upper portion hammer and the lower member rotation Figure 1 1 shows GH 40 hammer with the two sections delineated and the critical parts identified Service Manual Organization Safety instructions are provided in Section 2 0 Sections 3 0 through 8 0 cover servicing the hammer portion of the GH 40 hammer Sections 9 0 through 22 0 detail servicing the rotation member of the GH 40 hammer Help From Geoprobe Help is available In fact why don t you call us before you tear into your hammer for the first time The GH 40 hammer is our creation and quite frankly we are rather proud of it We will be happy to discuss any problems you may have over the phone Simply call us anytime between 8 00 a m and 5 00 p m central time Monday through Friday at 1 800 GEOPROBE 1 800 436 7762 Just request customer service and we ll help you with troubleshooting walking you through any servicing step that may seem difficult Which Way Is Which For purposes of clarity in this manual left refers to the driver s side of the vehi
16. adapter from the nitrogen fill hose at the quick connect fittings Service Manual Hammer Member Page 20 Geoprobe GH 40 Hammer 7 14 Snug the lock nut on the nitrogen charge valve loosened in Step 7 3 using a rachet and a 5 8 socket Fig 7 20 DO NOT OVERTIGHTEN 7 15 Listen fora hissing sound around the charge valve and accumulator housing Check for dripping oil around the base plate and piston ifhammer member is removed as in Figure 7 12 or from the hex drive ifthe hammer is installed as in Figure 7 13 Obvious leaks such as those described above would indicate a defective accumulator diaphragm in the hammer member If the accumulator diaphragm has failed the hammer member must be sent to the Geoprobe factory in Salina Kansas for repair 7 16 Reinstall the nitrogen charge port cap that was removed in Step 7 2 7 17 Nitrogen recharge is complete IMPORTANT Do not transport the nitrogen gas cylinder without first removing the regulator assembly Always secure the cylinder during transport to prevent shifting or rolling while the vehicle is in motion These are important safety issures as the cylinder can be propelled at a high rate of speed if the regulator or valve were to be damaged during transport Fig 7 1 Nitrogen gas cylinder with Fig 7 2 Charge valve adapter left shown with pressure regulator assembly nitrogen fill hose quick connect coupler Fig 7 3 Remove cap from nitrogen charge Fig
17. ally hang to the side of the hammer clear of the work area Fig 13 10 Remove the two socket head cap screws from the hydraulic motor mounting holes Figs 13 11 A B using a 3 8 hex bit and socket wrench To release the hydraulic motor place the foot of a small crow bar between the 12 tooth sprocket and the top of the gear drive box Fig 13 12 A small amount of prying may be necessary to release the sprocket from the hydraulic motor shaft Lift the hydraulic motor off the gear drive box Fig 13 13 Hold hand under 12 tooth sprocket to catch the sprocket once the hydraulic motor shaft releases it Service Manual Rotation Member Page 43 Geoprobe GH 40 Hammer 13 18 Place hydraulic motor in a plastic bag even if ports have been plugged to ensure foreign objects do not contaminate hydraulic system Fig 13 14 13 19 Remove hydraulic motor spacer Fig 13 15 13 20 Removal of the hydraulic motor is complete 7 Geoprobe Fig 13 2 Remove chain cover bolts and lock washers Fig 13 1 Position GH 40 Hammer to chest height for hydraulic motor removal Nd NI 2 smi 39 uzdo N3HM 3 43502 NIVK 22 z 53 c 54 2 Fig 13 3 Remove chain cover plate Fig 13 4 Loosen set screws at base of 12 tooth sprocket Service Manual Rotation Member Page 44 Geoprobe GH 40 Hammer 11 FEE Fig 13 5 Remove socket head cap screws Fig 13 6 Pull
18. alve is complete Fig 12 11 Service Manual Rotation Member Page 39 Geoprobe GH 40 Hammer Fig 12 1 Lubricate new O rings with oil grease Fig 12 2 Install O rings on valve spool Fig 12 3 Install valve spool retainer ring at handle Fig 12 4 Reattach rotation valve handle on valve end of valve spool spool aligning valve spool slots and handle position as shown Fig 12 5A Apply hydraulic oil or grease to valve Fig 12 5B Apply hydraulic oil or grease to inside spool diameter of valve spool cylinder Service Manual Rotation Member Page 40 Geoprobe GH 40 Hammer Fig 12 6 Rotate valve spool while inserting into valve body Fig 12 9B Attach hammer rotation valve to hydraulic motor Service Manual Rotation Member Page 41 Fig 12 7 Install second retainer ring on hydraulic motor side of valve body Fig 12 94 Hammer rotation valve is ready to be attached to hydraulic motor Geoprobe GH 40 Hammer Fig 12 10 Reattach hydraulic hoses to Fig 12 11 Assembly and installation of rotation valve hammer rotation valve is complete Service Manual Rotation Member Page 42 Geoprobe GH 40 Hammer 13 0 HYDRAULIC MOTOR REMOVAL CAUTION All hydraulic connections and hydraulic oil must be kept free from foreign materials Failure 13 1 13 2 13 3 13 4 13 5 13 6 13 7
19. amage the carrier vehicle if overextended Turn off deactivate hydraulic system and shut off vehicle engine Remove the two chain cover bolts and lock washers using a 9 16 wrench Fig 15 2 Remove chain cover plate Fig 15 3 Loosen set screws at the base of the 12 tooth sprocket with a 1 8 or 5 32 allen wrench Fig 15 4 Loosen the two socket head cap screws in hydraulic motor mounting holes using a 3 8 hex bit and socket wrench Fig 15 5 Remove socket head cap screws Fig 15 6 Place the foot of a small crow bar between the 12 tooth sprocket and the top of the gear drive box Using a small amount of prying if necessary release the sprocket from the hydraulic motor Fig 15 7 Pull hydraulic motor away from gear drive box Fig 15 8 Rest hydraulic motor against the control panel Fig 15 9 Remove 12 tooth sprocket from drive chain Fig 15 10 Insert drill steel into hex drive and rotate drill steel until the connector link is near the hydraulic motor slot Fig 15 11 The chain may need to be guided around the hex drive sprocket Using a small pick remove connector link keeper Fig 15 12 Place connector link under hydraulic motor shaft slot and remove remaining two pieces of the connector link from drive chain Fig 15 13 To remove the chain from the gear drive box gradually pull one end of the drive chain from the rotation member If necessary rotate hex drive in a corresponding direction to assist in re
20. bolts 17 12 Liftrotation member out of hammer cradle Fig 17 10A Hammer rotation member and hydraulic motor are now removed from hammer cradle Fig 17 10B 17 13 Lay rotation member on a work bench 17 14 Remove drive chain and 12 tooth sprocket See Section 15 0 Drive Chain and 12 Tooth Sprocket Removal 17 15 Remove the four bolts and lock washers from the top plate using a 3 4 socket and socket wrench Fig 17 11 Service Manual Rotation Member Page 59 Geoprobe GH 40 Hammer NOTE The most efficient method used to disengage the top and bottom plates from the gear drive box 17 16 17 17 17 18 is to install the four bolts just removed from the top plate into the mounting holes on the side of the top and bottom plates Gently tap the bolts to help separate the plates from the gear drive box Fig 17 12 If necessary use a screwdriver to pry the top plate away from the gear drive box Fig 17 13 Take care not to damage the almuinum gear drive box or plastic shims Remove top plate from gear drive box Fig 17 14 Note location of the plastic shims which separate the gear drive box from the top and the bottom plate IMPORTANT Wear safety glasses during all hammering procedures 17 19 17 20 17 21 17 22 A large screwdriver may be necessary to pry the bottom plate of the gear drive box free in the same manner as the top plate Take care not to damage the aluminum gear drive box and plastic shims If
21. cle and right refers to the passenger side 2 0 SAFETY PRECAUTIONS Always deactivate the hydraulics and turn off vehicle engine before attempting to disassemble any parts of the Geoprobe unit Always seek assistance when removing the hammer member or the rotation member from the soil probing unit These components are heavy Seek assistance when installing the hammer member or the rotation member on the soil probing unit These components are heavy Any time impact is applied with hammer or any other device to any object safety glasses must be worn When removing installing or servicing this hammer always wear safety glasses When disconnecting hydraulic lines always wear safety glasses Hot or pressurized oil may be present and can cause injury Always wear steel toe boots when removing or installing the hammer member or rotation member of the GH 40 Hydraulic Hammer Service Manual Page 5 Geoprobe GH 40 Hammer AIR VENT S o ACCUMULATOR CHARGING PORT UPPER MOUNTING HOLE 2 HAMMER HYDRAULIC INLET PORT HAMMER MEMBER HAMMER HYDRAULIC RETURN PORT AIR VENT HYDRAULIC MOTOR L NE DI 2 HAMMER A 0Q p ROTATION 21 lt VALVE gus lw 2 ROTATION MEMBER AK C HAMMER ROTATION LEVER AK A gt ADJUSTABLE POSITION ORA LATCH BOLT LOWER MOUNTING HOLES ANVIL RETAINER CAP ASSEMBLY FIGURE
22. containing a small amount of hydraulic oil Small amount of multi purpose grease or wheel bearing grease N N Re RN Re NOTE A torque wrench is a necessary item for servicing the hammer member of the GH 40 hammer If you do not have a torque wrench available DO NOT attempt to service this hammer 3 5 What tools are required to recharge the hammer with nitrogen ITEM QUANTITY Open Ended Wrench adjustable 1 Open Ended Wrench 1 3 8 Socket Wrench 3 8 drive Socket 5 8 Cylinder of Industrial Quality Nitrogen Pressure Regulator Victor Model SR 4G Pressure Gauge 0 2000 psi Line Shut off Valve Charge Stem Adapter eee ee Service Manual Hammer Member Page 7 Geoprobe GH 40 Hammer 4 0 HAMMER MEMBER REMOVAL CAUTION Allhydraulic connections and hydraulic oil must be kept free from foreign materials Failure to do so will severely damage the hydraulic system of the hammer unit CAUTION The upper hammer member is heavy Do not attempt to remove it on your own Seek assistance when removing it from mounting brackets and rotation member NOTE Refer to Section 23 0 or 25 0 for instructions on removing a Hammer Brace Assembly or Rod 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 Grip Pull Assembly if either accessory is installed on your GH 40 Hammer Extend unit fully from vehicle Lower foot with Foot Control and raise hammer with Probe Control so that the rotation me
23. e Assembly and Installation 43 Hydraulic Motor Removal eevronnvenvernvenveennenneennennennennennnennsnnennsennennsennennsenneeneeer 47 Hydraulic Motor Installation essorornveevosnrenneennennrennennnennsennennesnnennenneennennsnnennsee 52 Drive Chain and 12 Tooth Sprocket Removal eese 57 Drive Chain and 12 Tooth Sprocket Installation 61 Hex Drive Gear Bearings and Seals Removal x mm 63 Hex Drive Gear Bearings and Seals Installation 71 Hammer Latch Removal Rotation Member Removed from Probe Unit 81 Hammer Latch Installation Rotation Member Removed from Probe Unit 83 Hammer Latch Removal ies s sehek eee sek k reke W kU Ee e He ke Ve se be weke ak soto 87 Hammer Latch Installation reonornrornrennvenrennvenneennenneennenneennenneennennnennennssnnennsseneen 89 Removal of Hammer Brace Assembly 93 Installation of Hammer Brace Assembly heeheeneneeneeeeeeeeeeeeeeekeeke 94 Removal of Rod Grip Pull Assembly hhheheerenreneeeeeeeeeekenee nenn 95 Installation of Rod Grip Pull Assembly rennornrvnnvenvennvenneennennennnenneennenneennenneennennee 96 Trouble
24. eir respective holes in the hammer member base plate Base plate bolt holes should be aligned Fig 8 1 This process will require some manipulation of the hammer member so that it will clear the top of the hammer cradle and hydraulic hoses as it is lowered onto the hammer alignment pins Loosely install base plate bolts and lock washers with a 15 16 socket and socket wrench Fig 8 2 Loosely install top mounting bolt lock washer and nut Fig 8 3 Tighten base plate bolts evenly and securely with a 15 16 end wrench or a 15 16 socket and a socket wrench Fig 8 4 Securely tighten top mounting bracket bolt lock washer and nut with a 15 16 end wrench a 15 16 socket and a socket wrench Fig 8 5 Remove plastic bags or hydraulic fitting caps from the hammer inlet and return hoses Fig 8 6 Reconnect the identified hammer inlet and return hoses to original positions on the hammer member using a 7 8 end wrench Fig 8 7 Check all bolts and fittings for tightness Hammer member installation is complete Service Manual Hammer Member Page 24 Geoprobe GH 40 Hammer fn ecoprobe GH 40 Fig 8 2 Install base plate bolts Fig 8 1 Lower hammer member onto hammer alignment pins lGeoprebe GH 46 1 Fig 8 4 Tighten base plate bolts evenly and securely Fig 8 3 Install top mounting bolt lock washer and nut Service Manual Hammer Member Page 25 Geoprobe GH 40 Hamme
25. ermatex Aviation Forma Gasket to the chain cover plate mating surface on the gear drive box Fig 14 13 14 12 Attach chain cover plate to gear drive box with original two cap screws and lock washers using a 9 16 wrench Fig 14 14 IMPORTANT Thelower gear box shim must rest between the chain cover plate and the bottom plate of the hammer Take care not to wrinkle this shim when installing the chain cover plate 14 13 Install both hydraulic motor O rings one in each port Fig 14 15 14 14 Secure hammer rotation valve to hydraulic motor with the four socket head cap screws originally used Fig 14 16 Using a 1 4 hex bit and socket or allen wrench tighten cap screws securely in a crisscross pattern NOTE Early model GH 40 rotation members utilize lock washers in securing the valve body to the hydraulic motor 14 15 Check all fasteners for tightness 14 16 Installation of hydraulic motor is complete Fig 14 17 Service Manual Rotation Member Page 48 Geoprobe GH 40 Hammer Fig 14 1 Apply sealant to both sides of hydraulic Fig 14 2 Place hydraulic motor spacer on gear box motor spacer and align bolt holes Fig 14 3 Align half moon key in hydraulic motor shaft with key way in 12 tooth sprocket Fig 14 4 Turn hex drive by hand or with 1 hex drill steel may be used to achieve alignment Service Manual Rotation Member Page 49 Geoprobe GH 40 Hammer
26. et off the ground Raise hammer so that hammer rotation valve and hydraulic motor are at chest level Fig 11 1 Turn off deactivate hydraulic system and vehicle engine Relieve remaining pressure in hydraulic lines by working all levers up and down several times Fig 11 2 Identify the hydraulic hoses connected to the valve body Fig 11 3 Use two 7 8 open ended wrenches to remove the hydraulic fittings at the top and rear of the hammer rotation valve Fig 11 4 Use one wrench as a backup wrench The boss fittings which screw into the valve itself do not need to be removed Pull hoses away from valve body and cover open hose ends with plastic bags Fig 11 5A or with three 8 MJ hydraulic fitting plugs Fig 11 5B Remove the four socket head cap screws securing the hammer rotation valve to the hydraulic motor using a 1 4 hex bit and socket wrench Fig 11 6 NOTE Early model GH 40 rotation members utilize lock washers in securing the valve body to the 11 10 11 11 11 12 11 13 11 14 hydraulic motor Pull valve away from hydraulic motor Fig 11 7 Remove hydraulic motor O rings with small pick and store in a safe place 11 8 Plug hydraulic motor oil ports with plastic plugs Fig 11 9A or enclose entire hydraulic motor in a plastic bag Fig 11 9B Place rotation valve on a work bench Remove valve spool retainer ring from hydraulic motor side of valve body with a small pick or screwdriver Fig 11 10
27. g was removed Fig 10 5 Location of rotation valve lever Fig 10 6 Remove spool from valve body Fig 10 7 Remove O rings on valve spool Service Manual Rotation Member Page 31 Geoprobe GH 40 Hammer Fig 10 8 Lubricate valve spool Fig 10 9 Install new O rings cylinder Fig 10 10 Lubricate new O rings and valve 5 Fig 10 11 Insert valve spool into valve body using a with oil or grease back and forth rotation l Service Manual Rotation Member Page 32 Geoprobe GH 40 Hammer Fig 10 12 Position rotation valve lever Fig 10 13 Clean area around valve spool on valve body Fig 10 14 Install retainer ring on spool between hydraulic motor and valve body Service Manual Rotation Member Page 33 Geoprobe GH 40 Hammer 11 0 HAMMER ROTATION VALVE REMOVAL AND DISASSEMBLY CAUTION Allhydraulic connections and hydraulic oil must be kept free from foreign materials Failure to do so will severely damage the hydraulic system NOTE This section is provided so that the technician if desired can completely disassemble and 11 2 11 3 11 4 11 8 11 9 reassemble the entire hammer rotation valve Minor repairs such as oil leaks will not require complete disassembly and should be repaired as outlined in Section 10 0 Valve Spool O Ring Replacement Fully extend unit from vehicle Lower probe foot approximately 1 5 to 2 fe
28. h Broadway in Salina Kansas 67401 Telephone 1 800 436 7762 785 825 1842 Fax 785 825 2097 Geoprobe and Geoprobe Systems are registered trademarks of Kejr Inc in Salina KS Service Manual Page2 Geoprobe GH 40 Hammer GH40 Hydraulic Hammer Designed and built by Geoprobe Systems specifically for subsurface investigations Geoprobe Systems has produced this GH40 Hydraulic Hammer Service Manual to assist our customers with maintenance and repair of the GH40 hammer Every effort has been made to provide concise easy to follow instructions and to accurately describe and portray the necessary steps for servicing hammer components Any person performing service on the GH40 hammer should have a thorough mechanical background and experience in the overhaul of hydraulic machinery Improper servicing of the GH40 hammer may interfere with the hammer warranty if such is still in effect We at Geoprobe take pride in our product and our service If you have any questions regarding the operation care or service of the GH40 hammer or if you d just like to talk to any of our friendly Geoprobe personnel please call us at 1 800 436 7762 Service Manual Page 3 Geoprobe GH 40 Hammer Section 1 0 Section 2 0 Section 3 0 Section 4 0 Section 5 0 Section 6 0 Section 7 0 Section 8 0 Section 9 0 Section 10 0 Section 11 0 Section 12 0 Section 13 0 Section 14 0 Section 15 0 Section 16 0 Section 17
29. hammer rotation valve away from hydraulic motor Fig 13 7 Place hammer rotation valve in plastic bag and securely close Fig 13 9 Plug hydraulic motor oil ports with plastic plugs Service Manual Rotation Member Page 45 Geoprobe GH 40 Hammer o NOT OPERATE THIS MACHINE WITH LI Vo 2120 e DO NOT OPERATE THIS MACHINE WITH THE CHAIN COVER PLATE REMOVED THE CHAIN COVER PLATE REMOVED Fig 13 10 Rotation valve should hang away from Fig 13 11A Loosen socket head cap screws from hammer hydraulic motor mounting holes DO NOT OPERATE THIS MACHINE WITH THE CHAIN COVER PLATE REMOVED Fig 13 12 If necessary carefully pry sprocket from hydraulic motor shaft Fig 13 11B Remove socket head cap Screws Service Manual Rotation Member Page 46 Geoprobe GH 40 Hammer Fig 13 13 Lift hydraulic motor off gear Fig 13 14 Place entire hydraulic motor drive box in plastic bag Fig 13 15 Remove hydraulic motor spacer from gear drive box Service Manual Rotation Member Page 47 Geoprobe GH 40 Hammer 14 0 HYDRAULIC MOTOR INSTALLATION CAUTION Allhydraulic connections and hydraulic oil must be kept free from foreign materials Failure to do so will severely damage the hydraulic system 141 Lightly coat both sides of hydraulic motor spacer with Permatex Aviation Forma Gasket or equivalent Fig 14 1
30. ith hydraulic oil or grease Fig 12 5B Align the valve spool with the valve spool cylinder in the valve body Recheck the valve spool handle position Fig 12 6 Rotate the spool back and forth while pushing the valve spool into the valve body This is an important step because pushing the valve spool directly into the valve body without rotation can cause the sharp edges of the valve body to damage the valve spool O rings Damaged O rings will leak hydraulic fluid Once the valve spool bottoms out against the valve spool retainer ring install the second retainer ring on the hydraulic motor side of the valve body Fig 12 7 The valve spool handle should be positioned between the 9 and 12 o clock position or between the two stop pins Install O rings into hydraulic motor making sure O rings are completely seated in their ports Fig 12 8 The hammer rotation valve is ready to be reattached to the hydraulic motor Fig 12 9A Attach the hammer rotation valve to the hydraulic motor with the original socket head cap screws Fig 12 9B using a 1 4 hex bit and socket wrench to tighten the cap screws securely in a criss cross pattern NOTE Early model GH 40 rotation members utilize lock washers in securing the valve body to the 12 11 12 12 12 13 hydraulic motor Reattach marked hydraulic hoses to their original positions Fig 12 10 Check all nuts bolts and fittings for tightness Assembly and installation of hammer rotation v
31. kt 5021T 1in Hex Drive Shim Gearbox 0 005 Bolt Shld Sh 3 4 10NC 7 8 7 8 Ring Rtng 2 95 OD x 0 049 Thk Cap Ring Collar Rtng Latch Hammer Spg Comp 2 57 ID x 1 62 x 0 11 Wire Seal 2in Sft Plate Bottom Valve Body Spacer Mot Hyd Valve Spool Sprkt 50 12T x 1in Bore Plate Cover SS Ball 0 375 Motor Hyd 9 7 cu in LH Rotn Lever Spg Comp 0 345 OD x 1 25 x 0 07 Wire Ring Rtng 0 889 OD x 0 031 Thk Wash Split Lock 1 2 Zn O ring 116 Buna 70 Bolt HH 1 2 13NC x 4 5 GR5 Zn Hose Hyd 8M3K 8FJX45S 8FJX 14in Bolt HH 3 8 16NC x 0 75 x GR5 Zn Wash Split Lock 3 8 Zn Bolt Sh 1 2 13NC x 1 75 Bolt Sh 5 16 18NC x 2 5 Bolt HH 5 8 11NC x 2 GR5 Zn Wash Split Lock 5 8 Zn Chain Roller 50 Screw Mach Rh SI 10 32 x 0 5 Zn O ring 112 Buna 80 Chain Link Offset 50 Chain Link Conn 50 Pin Spg 0 188 x 1 Knob Plstc 7 16 20NF Hammer Upper Assm Ftg Hyd 8MB 8MJ Plug Stl HH 8MB Anvil Hammer GH40 Plug Pipe Stl 1 8 27 NPT Bolt Sh 5 16 18NC x 0 375 Decal Rotqry Member GH40 Decal Vinyl Warning Tie Rod Nuts Decal Vinyl Caution Chain Cover Plate Decal Vinyl Geoprobe GH40 Decal Vinyl Hammer Rotation GH40 Decal Vinyl Hammer Rotation GH40 Geoprobe GH 40 Hammer 10 0 VALVE SPOOL O RING REPLACEMENT The valve spool O ring may need to be replaced if hydraulic oil is leaking from around the spool on either side of the gear box valve body CAUTION All hydraulic connections and hydraulic oil must be kept free from foreign materials Failure to do so
32. mber of the hammer is approximately waist high Fig 4 1 Turn off deactivate hydraulic system and vehicle engine Relieve remaining pressure in hydraulic lines by working all levers up and down several times Fig 4 2 Mark and disconnect inlet and return hoses from hammer Fig 4 3 using a 7 8 open ended wrench Cover hydraulic lines with a small plastic bag and secure with a rubber band Fig 4 4A or plug the hydraulic lines with two 8 MJ plugs Fig 4 4B Seal hammer inlet and return fittings with two 8 MJ caps Fig 4 5 Remove base plate bolts with a 15 16 socket and socket wrench Fig 4 6A B Remove top mounting bracket bolt with a 15 16 socket socket wrench and end wrench Fig 4 7 Carefully pry hammer member loose with a pry bar placed under the side rod nut lip and on top ofthe rotation member bolts Fig 4 8 Lift hammer member up and away from the top of the hammer cradle and rotation member Fig 4 9 Removal of hammer member is complete Fig 4 10 Service Manual Hammer Member Page 8 Geoprobe GH 40 Hammer Fig 4 2 hydraulic pressure in lines by working and down Fig 4 1 Positioning the GH 40 hammer for servicing Fig 4 4A Cover ends on all hydraulic lines re moved from hammer with small plastic bags Option 1 Fig 4 3 Disconnect the hydraulic lines Service Manual Hammer Member Page 9 Geoprobe GH 40 Hammer Fig 4
33. motor d Fig 11 9A Plug hydraulic motor oil ports with plastic plugs Option 1 Fig 11 9B Enclose hydraulic motor in a plastic bag Option 2 Service Manual Rotation Member Page 37 Geoprobe GH 40 Hammer Fig 11 10 Remove valve spool retainer ring Fig 11 12 Remove hammer rotation valve handle Fig 11 14 Remove O rings from valve spool Service Manual Rotation Member Fig 11 13 Remove remaining retainer ring from valve spool Geoprobe GH 40 Hammer 12 0 HAMMER VALVE ASSEMBLY AND INSTALLATION CAUTION Do not scar or scratch valve spool or bore of cylinder during assembly 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 12 10 Make sure all parts used in this procedure are clean Lubricate new No 116 O rings with a coat of hydraulic oil or grease Fig 12 1 Install one O ring in each of the two grooves provided on the valve spool taking care not to nick them on the sharp edges of valve spool Fig 12 2 Install one valve spool retainer ring at the slotted handle end of the valve spool Fig 12 3 Reattach valve spool handle to the valve spool cylinder with the original lock washer and screw Fig 12 4 The valve spool slots and handle position should correspond to the alignment as shown in the photograph Liberally coat the valve spool Fig 12 5A and the inside diameter of the valve spool cylinder w
34. moval Removal of drive chain and 12 tooth sprocket is complete Service Manual Rotation Member Page 53 Geoprobe GH 40 Hammer Fig 15 1 Position unit for servicing Fig 15 2 Remove chain cover bolts and lock washers Fig 15 5 Loosen socket head cap screw in Fig 15 6 Remove socket head cap screws hydraulic motor mount Service Manual Rotation Member Page 54 Geoprobe GH 40 Hammer Fig 15 7 Carefully pry sprocket from hydraulic Fig 15 8 Pull hydraulic motor away from gear motor shaft drive box Fig 15 10 Remove 12 tooth sprocket from drive chain Fig 15 9 Rest hydraulic motor against control panel Service Manual Rotation Member Page 55 Geoprobe GH 40 Hammer Fig 15 12 Remove connector link keeper Fig 15 11 Insert drill steel into hex drive to achieve proper connecter link position Fig 15 13 Remove remaining pieces of connector link Service Manual Rotation Member Page 56 Geoprobe GH 40 Hammer 16 0 DRIVE AND 12 5 INSTALLATION 16 1 Cuta new piece of 50 drive chain with a chain detacher U S Tsubaki No D 35 Chain Detacher see Fig 16 1 so that the chain measures 21 inches or 17 links Fig 16 2 16 2 Attach one new offset link to the drive chain Fig 16 3 The eye of the cotter pin should rest against the flat side of the offse
35. nug nuts very slightly in a crisscross pattern IMPORTANT Always use a torque wrench to tighten side rod nuts Failure to do so will void hammer warranty 6 12 Usingatorque wrench and a 15 16 socket torque the side rod nuts to 30 foot pounds in a crisscross pattern Fig 6 13 Torque side rod nuts to 45 foot pounds in the same crisscross pattern 6 13 Base plate seal installation is complete Fig 6 14 Service Manual Hammer Member Page 16 Geoprobe GH 40 Hammer Fig 6 1 5 cavity on base plate should face upwards during installation Fig 6 2 Push or wiper into bottom seal cavity Fig 6 3 Seal washer is placed on top of D or H Fig 6 4 Push cup seal onto seal washer wiper Service Manual Hammer Member Page 17 Geoprobe GH 40 Hammer Fig 6 5 Installation of base plate O ring onto base Fig 6 6 Apply hydraulic oil to sealing surfaces of plate cup seal and D or H wiper Fig 6 7 Apply grease to installed base plate Fig 6 8 Lubricate exposed surface of hammer O ring piston Fig 6 9 Sub seal vent port must face inlet and Fig 6 10 Slide base plate onto side rods and piston return fitting side of hammer Service Manual Hammer Member Page 18 Geoprobe GH 40 Hammer Fig 6 11 Base plate O ring rests against flow sleeve Fig 6 12 Side rod nuts must be installed loosely and tube evenly Fig 6 13 First torque side rod nuts to 30 fo
36. ot Fig 6 14 Completed base plate seal installation pounds in a crisscross pattern then torque to 45 foot pounds in a crisscross pattern Service Manual Hammer Member Page 19 Geoprobe GH 40 Hammer 7 0 RECHARGING NITROGEN IN GH 40 Should the Geoprobe operator experience inconsistency with the percussion function of the GH 40 Hammer one possible culprit could be a lack of nitrogen charge in the hammer member accumulator chamber The percussion function may lack snap or completely fail as a result of inadequate nitrogen charge Though hammer failure due to a lack of nitrogen is rare recharging the hammer member will eliminate the possibility that an inadequate nitrogen charge is contributing to hammer member failure NOTE The following recharge procedure requires the use of a cylinder of industrial quality nitrogen gas pressure regulator assembly Fig 7 1 and charge valve adapter Fig 7 2 These are included in the GH 40 Nitrogen Charge Kit FA3000K available from Geoprobe Systems 7 1 Fold the probe derrick into the vertical position lower the foot onto the ground and raise the hammer to approximately waist level Shut off the power unit engine 7 2 Remove the cap from the nitrogen charge port using 1 3 8 wrench or socket as shown in Figure 7 3 This will provide access to the nitrogen charge valve shown in Figure 7 4 7 3 Loosen the lock nut on the nitrogen charge valve by turning it counterclockwise one com
37. paint mark makes a good check Cover exposed end of hammer with a clean shop rag NOTE Recent hammer improvements have replaced the D wiper with an H wiper The H 5 4 wiper s physical appearance resembles that of the cup seal The H wiper requires a different base plate to accommodate its lower sealing surface Be sure to determine which wiper your hammer member utilizes THE D WIPER AND THE H WIPER ARE NOT INTER CHANGEABLE Cup seal seal washer and D or H wiper should be contained in base plate Fig 5 5 CAUTION Do not scratch or nick any machine surface while replacing seals 5 5 5 6 5 7 5 8 5 9 Cup seal may remain on the piston and can be easily removed by hand or with a small pick Fig 5 6 Carefully pry cup seal seal washer and or H wiper out of the base plate with small pick or screwdriver Fig 5 7 Observe seal location and orientation prior to removal Remove base plate O ring with a small pick or screwdriver Fig 5 8 Thoroughly wash base plate and side rod nuts in solvent Dry all parts with compressed air Hammer member base plate seal removal is complete Service Manual Hammer Member Page 12 Geoprobe GH 40 Hammer le ACCUMULATOR EU P HOUSING D Wiper Cross Section H Wiper Cross Section SIDE ROD NOTE The base plate seal cavities are different sizes for a D or H wiper A D wiper will not fit in a base plate machined
38. plate over in the bench vise every few strikes so the bearing race will be pushed out of the bottom plate evenly Removal of hex drive gear bearings and seals is complete Service Manual Rotation Member Page 60 Geoprobe GH 40 Hammer
39. plete revolution with a 5 8 socket Fig 7 5 7 4 Thread the large hex cap of the charge valve adapter into the nitrogen port on the hammer Fig 7 6 Install the adapter finger tight but with sufficient torque to seat the O ring within the port 7 5 Thread the center stem of the charge valve adapter in toward the hammer until it is finger tight Fig 7 7 7 6 Attach the quick connect coupler on the end of the nitrogen fill hose to the quick connect nipple on the charge valve adapter as shown in Figure 7 8 7 7 Ensure that the line pressure in the nitrogen fill hose is set at zero by turning the regulator tee handle Fig 7 9 counterclockwise until it turns freely 7 8 Open the main valve on the nitrogen cylinder Fig 7 10 by turning the handle counterclockwise 7 9 Slowly turn the regulator tee handle Fig 7 9 clockwise until the line pressure gauge reads 650 psi IMPORTANT DO NOT overcharge the system Charging the system beyond 650 psi will rupture the accumulator diaphragm or otherwise damage the hammer 7 10 Close the main valve on the nitrogen gas cylinder Fig 7 10 by turning the handle clockwise 7 11 Unthread the charge valve adapter center stem several revolutions out from the hex Fig 7 11 7 12 Rotate the regulator tee handle Fig 7 9 counterclockwise until the line pressure gauge reads 650 psi pressure is releaved 7 13 Remove the charge valve adapter from the hammer by unthreading the large hex cap Detach the
40. r Fig 8 6 Remove plastic bags or caps from hammer inlet return hoses la l da Fig 8 5 Tighten top mounting bolt lock washer and nut Fig 8 7 Reconnect hammer inlet and return hoses to hammer member Service Manual Hammer Member Page 26 Geoprobe GH 40 Hammer 9 0 SERVICING THE ROTATION MEMBER 9 1 When is service necessary When the hex drive no longer rotates When the lower stem ofthe hex drive gear exhibits noticeable lateral side to side fore or aft movement When the chain develops noticeable slack indicated by easy manual rotation of the hex drive gear stem before chain tension halts stem rotation When the retainer groove at the bottom of the hex drive exhibits excessive wear 9 2 What servicing can be done in the field Except for emergencies rotation member service should be undertaken in a shop setting Rotation member service demands special tools and a clean work environment usually not present in the field 9 3 What tools are required to service the rotation member portion of the GH 40 Hammer Fig 9 1 ITEM QUANTITY Socket Wrench 1 2 drive 1 Socket Wrench 3 8 drive 1 Socket 7 8 1 Socket 3 4 1 Socket 9 16 1 Open Ended Wrench 9 16 1 Allen Wrench 1 8 1 Allen Wrench 5 32 1 Hex Bit 1 4 or Allen Wrench 1 Hex Bit 3 8 or Allen Wrench 1 Hex Bit 7 16 or Allen Wrench 1 Flat blade Screwdriver 1 8 MJ Hydraulic Fitting Caps Optional 2 8 MJ
41. removal of these components CAUTION Hammer member and rotation member are heavy Assistance is required to handle them safely Do not attempt to lift them by yourself 17 1 Remove hammer member See Section 4 0 Hammer Member Removal Fig 17 1 17 2 Leave unit in hammer member removal position 17 3 Hydraulic system should still be turned off deactivated and vehicle engine should be turned off 17 4 Remove the two chain cover plate bolts and lock washers using a 9 16 wrench Fig 17 2 17 5 Remove chain cover plate Fig 17 3 17 6 Loosen the set screw at the base of the 12 tooth sprocket with a 1 8 or 5 32 allen wrench Fig 17 4 17 7 Remove the two socket head cap screws from hydraulic motor mounting holes using a 3 8 hex bit and socket wrench Fig 17 5 17 8 Lift hydraulic motor off gear drive box Fig 17 6 A small amount of prying may be necessary to release the sprocket from the hydraulic motor shaft Place a small crow bar between the 12 tooth sprocket and the top of the gear drive box if prying is necessary Hold hand under sprocket to catch sprocket when hydraulic motor shaft releases it 17 9 Remove the 12 tooth sprocket from the drive chain Fig 17 7 17 10 Rest hydraulic motor on control panel Fig 17 8 17 11 Remove the four lower mounting bolts on the rotation member using a 3 4 socket and socket wrench Figs 17 9A B Assistance will be required to hold the rotation member while removing the final two
42. t link connector pin Bend both fingers of the cotter pin so that it will not slip out of the half link connector pin 16 3 Coil chain so that it fits into gear drive box The offset link cotter pin should face the cover plate side of the gear drive box Fig 16 4 16 4 Install drill steel or equivalent tool with 1 hex into hex drive and feed the end of the chain without the half link into and around the hex drive gear Fig 16 5 16 5 Once the chain has started to engage the drive sprocket slowly and carefully rotate the drill steel in a corresponding direction When the chain is visible on the opposite side of which it entered guide the chain out with your finger If it is not guided the chain will jam between the drive gear box 16 6 Continue to rotate the drill steel and feed the chain until the leading edge of the chain the link which first engaged the hex drive gear extends far enough to reach the hydraulic motor shaft slot Fig 16 6 16 7 Connect the loose ends of the chain with a new connector link and connector link keeper Fig 16 7 16 8 Place a new 12 tooth sprocket in the chain under the hydraulic motor shaft slot Fig 16 8 16 9 Install hydraulic motor See Section 14 0 Hydraulic Motor Installation eliminating Steps 14 13 and 14 14 NOTE Hydraulic hoses remain attached to the hammer rotation valve during installation of the hydraulic motor 16 10 Installation of drive chain and 12 tooth sprocket is complete
43. will severely damage the hydraulic system of the hammer 10 1 Fully extend unit from vehicle 10 2 Lower foot with Foot Control and raise hammer with Probe Control so that the hammer rotation valve and hydraulic motor are at chest level Fig 10 1 10 3 Turn off deactivate hydraulic system and vehicle engine 10 4 Relieve remaining pressure in hydraulic lines by working all levers up and down several times Fig 10 2 10 5 Using an O ring pick remove the small retainer ring which is situated between the hydraulic motor and the valve body Fig 10 3 10 6 With a clean wipe the area around the spool where the retainer ring was removed Fig 10 4 If compressed air is available blow debris from around retainer ring area CAUTION Take special care to be sure spool is free of any dirt or burrs 10 7 Note location of rotation valve handle Fig 10 5 10 8 Using a slight back and forth rotation movement pull the spool out of the valve body Fig 10 6 CAUTION Do not scratch valve spool or valve cylinder when removing O rings 10 9 Use an O ring pick to remove the O rings on the valve spool Fig 10 7 10 10 Leave hammer rotation valve handle attached to valve spool for proper spool alignment during installation 10 11 Thoroughly wash valve spool in solvent and dry with compressed air 10 12 Lubricate valve spool cylinder with a coat of oil or grease Fig 10 8 10 13 Install new O rings on valve spool taking care not to nick
44. your hammer member utilizes THE D WIPER AND H WIPER ARE NOT INTERCHANGEABLE 6 1 Place base plate on a clean work bench with seal cavity facing upwards Fig 6 1 6 2 Depending upon your hammer insert D wiper with lip and shoulder facing downwards into bottom seal cavity OR install H wiper with cup surface up Push wiper in manually Fig 6 2 If using the H wiper the small tapered protruding surface should be inserted into the base plate first This surface should mate with the chamfered shoulders 6 3 Place seal washer on top of D or wiper Fig 6 3 6 4 Push cup seal with lip and recession facing upwards onto seal washer Fig 6 4 6 5 Install base plate O ring onto base plate taking care not to damage O ring Fig 6 5 6 6 Apply hydraulic oil on the sealing surface of the cup seal and D or H wiper Fig 6 6 6 7 Apply a thin film of grease on the installed base plate O ring Fig 6 7 6 8 Lubricate the exposed surface of the hammer piston with a light film of hydraulic oil Fig 6 8 CAUTION Never use a hammer to force hydraulic components together 6 9 Slide the base plate onto side rods and piston making sure that the seals and piston remain aligned Fig 6 10 6 10 Push base plate forward until base plate O ring contacts the flow sleeve tube Fig 6 11 6 11 Install side rod nuts 4 loosely with a 15 16 socket and socket wrench Fig 6 12 Base plate and O ring should be drawn into flow sleeve S
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