MKB HYDRAULIC HAMMER OPERATION MANUAL MKB2100V MANUFACTURER KONAN ELECTRIC CO., LTD. KONAN CONSTRUCTION MACHINERY COMPANYINTRODUCTION We appreciate very much your purchase of “MKB hydraulic hammer”. ‘The MKB hydraulic hammer you have selected is the most advanced, high-performance hydraulic hammer. ‘This operation manual consists of two parts: part 1 cover the precautions for handling of MKB hydraulic hammer: part 2 deals with inspection and repairs. In order to achieve the highest efficiency from your MKB hydraulic hammer at minimum maintenance cost, please read this manual carefully before you begin operation. It should be noted that we shall not assume responsibility for losses and/ or damages incurred by any usage or maintenance not described in this manual. ‘The contents of this manual are subject to change without prior notice.SPECIFICATIONS AND STRUCTURE OF HYDRAULIC HAMMERWARNING ‘This manual is drawn up for the proper use of hydraulic hammer which is attached to base machine such as hydraulic excavator. ‘The hammer manufacturer can not directly supervise your usage, operation, inspection and maintenance of hydraulic hammers. So, you are responsible for the safety in carrying, cout these works. ‘This manual is made as guidance in the safety manner and safety requirement for the regular operation and maintenance of hydraulic hammers, ‘This manual describes important safety information. Read and thoroughly understand this manual atteched to the hydraulic hammer, Also read and thoroughly understand the instruction manual of the base machine such as hydraulic excavator, to which hydraulic hammer is attached, Bosides of this instruction manual, follow the safety information which may be contained in the sefety sign on the machine (.e.; caution plate or warning label, hereunder called “safety sign”) as well as regulations, laws, rules, insurance clauses and so on. Additional caution may be required depending on the condition of work and job environment. ‘This manual put X marks on the illustrations that indicates dangerous working procedures and circumstances. ‘The illustrations of this manual do not express the whole contents of the text but they are used to drew an attention to the text. In this manual, the base machine including hydraulic oxcavator which is attached with hydraulic hammer is called “Excavator”.TABLE OF CONTENTS PART 1 PRECAUTION FOR HANDLING 1, BEFORE OPERATION streereeseeseeeereeeseeee eee 2, DURING OPERATION< + tes eeceeceeeeeeeeeeeeeee eee eeeeeeseeeee eed AFTER OPERATION 4, INSPECTION AND MAINTENANCE ++ 7 5. DAILY INSPECTION vrs serseereeereeteeeeeeees PART 2. INSPECTION AND REPAIR 1. HYDRAULIC HAMMER DIMENSIONAL DRAWING + ++++eeereeeeeee 2225 HYDRAULIC HAMMER CROSS SECTIONAL DRAWING +++ ++++++++++26 3. BRACKET INSTALLATION SKETCH vertserersees serene -+30 4, CHISELS +eeteeceeeeeesceseeereeeeeeeseeenees +133 5. PIPING ACCESSORIES +++++sseseeeeeeeeeees sreseeee ed 6. TOOLS GAS CHARGING EQUIPMENT AND GAS PRESSURE +++ soe o86 8. OPERATING PRINCIPLE + 9. MAINTENANCE AND INSPECTION ++ +40 10, DISASSEMBLE AND INSPECTION t+rsetsrettsesees Peer 11, TROUBLESHOOTING percePart 1 PRECAUTION FOR HANDLING 1. Before operation (2) QUALIFICATION ‘The hydraulic hammer must be operated by qualified personnel (@ STUDY INSTRUCTIONS Improper operation, maintenance and/ or repair may result in severe injury or death, Study this manual and the instructions for both your particular hammer and excavator, and fully understand their controls, inspections and maintenance, Don’t operate the machine until you fully understand all these items. Keep this manual with your excavator. Ifyou have any inquiry about the contents of this manual, contact with the manufacturer or the distributor in your area. Severe injury or death may result if the instructions or warnings are ignored. Don't ignore what you don’t understand. Make sure to read all this instructions and warnings and fully understand them before operation. In the event thet the instruction manual or safety sign is lost or become unreadable, immediately place an order for them with an employer, distributor or menufacturer, end provide excavator with them. (3) BAN ON OPERATION UNDER OVERFATIGUE AND ALCOHOL DRINKING Operation under over~fatiaue, lack of sleep or the influence of alcohol, drug will lead inattentive and may cause an accident, Do not operate the excavator or hydraulic hammer in bad physical condition or under the influence of alcohol, drug. It is recommended to undergo a periodic medical examination for safe operation. (4) SAFETY WEARS Don’t wear loose clothes which may be entangled with the instrument in the operator cabin easily. Wear proper clothes and pay attention to the sleeves or hems of trousers and shoelaces. Don’ t wear clothes stained with oil as it may catch fire.(5) WEAR OF PROTECTIVE GEARS Be sure to wear safety helmet and safety boots when operating the machine, Wear safety glasses, anti-dust mask, ear protection and so on, if needed. Check the protection gears that they are fully functional before weari (© KEEP RULES OF THE WORK SITE Pollow the prohibitions, cautions and working procedure determined in the work site for safety. If the work is jointly done by more than two machines at the same place, determine a signal person and signals. (7) JUDGING CIRCUMSTANCE AT JOB SITE Works have to be done according to the condition and circumstances of the job site. Investigate and record the conditions in the job site beforehand to avoid any accidents such as machine’ s falling off or collapse of foundation. Take necessary measures such as keeping off, placing a guide or reinforcing the foundation and so on for dangerous area. More examples are shown below When work site is darks light up job site When work site is close to high-voltage cables+++make arrangements with the power company in advance to station a watchman or take other safety measurements. When work site is dangerous area such as under cliffs: * suse excavator with head~guarded cabin or put FOPS( Falling Object Protective Structure) in place. (8) CHECKING THE MACHINE BEFORE STARTS. At first make sure to attach the hammer to the manufacture’ s recommended excavator. Ifthe excavator is small for the hammer, the excavator may lose balance and may tip over. When using quick coupler of attachment, the total weight increases so much more for it. Check that total weight does not exceed the weight limit of excavator before mounting, Using non-serviced hydraulic hammer may cause unexpected accident and trouble, Bo sure to check the machine before starting job. If there is any abnormality, start job after repair.Major checkpoints: L Check for missing, falling off, damage or loosing of bolts and nuts, If the bolt or nut falls off during the operation, the other parts may come off, which has a risk of accident, Check if bolt or nut is missing, fallen off, damaged or looseness, Install, replace or retighten them if necessary. Check for crack or damage of chisel, holder pins and greasing. Check that there is no excessive gap between the chisel and bushing and that there are no deep scores or severe wearing on surface of the chisel. Replace the chisel and/ or bushing if they are damaged or excessively worn. ( Refer to paragraph 9.3, 9.7 in part 2) Never forget to grease on these sliding sections. When greasing, the chisel should be pressed against object. Check the quantity of hydraulic oil in the tank and possible oil contamination. Prior to each use, check the hydraulic oil tank contains sufficient oil and also ascertain the hydraulic oil is not contaminated. ‘The presence of foreign material such as metal fragments or metal powder in the hydraulic oil. J Indicates that the cylinder or the piston has been scored. J Which lead malfunction. Gas pressure in the piston gas chamber. ‘Check the gas pressure in the piston gas chamber. Ifit is low, charge with nitrogen gas as necessary. Refer to hammer specification, daily inspection in part 1, and paragraph 7 in part 2. Check for danger of falling of hydraulic hammer It may cause serious injury if hydraulic hammer falls off from the excavator or quick coupler during operation. Make sure that the hydraulic hammer is installed in the excavator or quick coupler securely.2. During operation (1) CHECK THE FUNCTIONS Unexpected movement of the machine causes a serious accident. Always make sure the machine position and direction of erawler. Operational method of the control levers, pedals and switches of the excavator may differ depending on model and manufacturer. There are some models of excavator which is equipped with the functions of selectable control mode setting. Before operating the excavator, be sure to check the operating method of each control levers, pedals and switches and fully understand how they work. (2) SAFETY TRAVELLING ‘To prevent accidents, travel on flat ground as much as possible and make sure to hold the hammer at 40 to 50 cm (15 to 20 inches) above the ground when traveling. ‘Traveling on slope involves a risk of turn over. Avoid traveling on the slope which exceeds the gradability or maximum angle which manufacturer specifies. When climbing up/down hill, lower the engine speed, raise the hammer 20 to 30cm(8.2 to 12.2 inches) above ground, and travel facing the uphill straightly. When the excavator slips on a slope or becomes unstable, lower the hammer onto the ground, and stop the machine. Sudden start and stop on unstable or slope ground may cause tipping over of the machine, Operate the control lever slowly. (3) PRECAUTIONS FOR SWINGING Operation near a building or wall may cause collision during turning, kicking workers around the machine or causing them to be crushed against the wall. @ Before turning the excavator, sound the hom to warn all personnel around the excavator. @ Make sure all personnel are clear off the turning area of the excavator before turning. @ Operate the machine in a place sufficiently away from a building or wall. @ Place a guide when visibility is bad or if necessary, OPERATION IN THE DANGEROUS JOB SITE Use the hammer by following the instruction of the supervisor. 4) Before operation investigate the condition of the job site to find out not only foreseeable danger but also potential danger and take necessary measures for safe operation. ‘© Operation on unstable ground (rough ,piled, inclined, narrow, on a building, +++) © Operation in heavy traffic area HEEEEEHEE tt © Operation in labored breathing area (indoor, in the tunnel, in dusty atmosphere containing asbestos, +++)© Operation on the locations of under ground utilities (cables, gas pipes, water pipes, sewage pipes, ++") © Operation at dangerous ares (on the cliff, under the cliff, in the building, *++) (5) DO NOT OPERATE SIDEWAYS Sideways stability of the excavator is generally not as good as lengthwise stability. Do not operate the hammer sideways, The excavator may be unstable and may be tilted or tipped over if the hammer is operated sideways. When swinging the excavator across the side, extract the boom and arm of the excavator and swing safely. (®)_ BEWARE OF FALLING AND PLYING OBJECTS ‘There is a risk of accident when rock or concrete fall unexpectedly and the fragments fly about during the operation of the hammer. Take care that the rock or concrete does not fall or fly to dangerous area, Use the excavator equipped with head guard or FOPS in case of operation in a dangerous place such as falling rock area. ( HOWTO OPERATE THE HAMMER Operate the hydraulic hammer in the following procedure. 1. Start the engine and wait until the needle of the temperature gauge moves, ( Idling ) 2. Run the engine at specified speed and select the power mode. 3. Press the chisel vertically against the object using a control lever. 4, Push down on the pedal to activate the hammer, the hammer begins to move. (8) USE THE HAMMER IN PROPER WAY 1, Hammer at right angle Always press the chisel end ot rieht angle to the object and break it up. Always at right angles to the surface of the object, /2. Press the hammer in the direction of the chisel point. Hsuebaisactal If the surface of the object is level, eciet ae lift the front end of the crawlers or chisel point. the front tires slightly off ground as Lift the front end of the crawlers or the front tires slightly off the, ground, illustrated . Ifthe hammer is not pressed in the chisel-point direction, recoiling sounds will be heard from the excavator stick. 3. Never operate with 90° angle between the stick and the ground, ‘The stick cylinder vibrates violently on operating as a result the stick cylinder and ete. on the hydraulic | excavator will be broken. WZ \ K 4. Never perform no load operation Always hammer with the chisel pressed x against the object. No load operation will cause an abnormal rise in the temperature of the hydraulic No load oil, loosening and damage to the bolts, operation If the chisel is not pressed sufficiently against the object, no load operation may result at times when crushing soft rocks. ‘The hammering sound will change if the chisel is used to hammer without a load.5. Never use the hammer as a pry-bar Breaking up a rock with the chisel twisted or shoved will subject the bolts and chisel and holder bushing Never pry the object off to faster wear and possible damaged. 6. Never hammer at the same point for more than 1 minute. Should the object refuse to break even after continuous hammering with the chisel at the same point for more than 1 minute, move the chisel to another point. Continued hammering at the same point will cause an abnormal rise in the temperature of the hydraulic oil. This may lead damage to the bolts and faster Change hammering point wear to the chisel. IE the object is not broken within Imin 7, Start with an outer edge against a large hard Begin frou the outside edge object If the object is large and hard, begin hammering O|#]o/4#/o with the chise! from the outside edge to break it most efficiently.8. Operate at the proper engine speed(rpm) { Always hammer with the engine running at the specified speed. \ Running up the engine will not increase the hammering force, but will only serve to raise the oil temperature. 9. Avoid hammering against bedrock In principle this kind of hammer is not suited to the breaking up of bedrock. Blasting must be done for breaking bedrock. 10, Do not use the hammer under water Do not dip any part of the hammer except the chisel into water or mud as Do not dip this may cause the hammer piston to into water rust and damage the hammer. LL. Do not break objects by dropping the hammer. Do not break objects by dropping the hammer, This will put an excessive strain on the excavator and will cause damage to parts of the hammer or x excavator.12. Do not move objects with the hammer Do not move objects by using the side of bracket or hammer. ‘This will cause damage to the bracket or bracket lock bolts as well as the stick and boom, 13. Do not hammer with the stroke end of the excavator cylinder Do not hammer with the stroke end of the hydraulic cylinder of the excavator. This will strain and possible damage the excavator. 14, Do not use the hammer for liting purposes Do not put wires on the hammer, bracket, ae or chisel for the purpose of lifting. This will cause damage to the hammer, bracket or chisel, and create dangers in \ operation. %(9) HOW TO CHANGE CHISEL 1. Beware of chisel’ s temperature Be careful not to touch the chisel and not to be burned as the chisel becomes very hot during and right after the hammering operation. 2, Chisel replacement procedure 1, Insert the bar provided in the tool box into the clamping pin hole and hit it until the clamping pin at opposite side comes out. (Leave the clamping pin inserted in the chisel holder) 2. Using the bar provided in the tool box, strike out the holder pin from the opposite side with a hammer. 3, Take the left and right holder pins off their holes to remove the chisel. ‘The weight of the chisel is usually heavier than its appearance. Be careful not to pinch. your fingers or hurt your back when removing or fitting the chisel. 4, Replace with a new chisel and then insert holder pins and clamping pins into the holes in reverse order described above, o (2) @ 3, Notes on handling of the chisels. The chisel and the holder bushing are susceptible to damage if mishandled, Never handle the chisel in the following manners.(2) Do not hang heavy objects from chisel. Do not use the chisel as a lever or to move an object. Do not hit it against a hard object. (2) Do not leave the chisel exposed to rain, when it is stored. (3) During transportation, chise] should be taken care of not to bang against one another. (4) Do not use a gas torch to heat any of the chisel. When a new chisel is installed to the hammer, sliding part of the chisel should be greased. And also warming up operation is requested at the soft object in stead of hard one. 4. Kinds of chisels, Chisels are available in three different types. ‘The seller does not warrant the hydraulic parts if the chisels are not genuine ones for MKB hydraulic hammer. pavements Demolishing foundations General civil engineering Point chisel R= Crushing pavements ‘*Demolishing concrete buildings Flat chisel = (E2== Flat~end chisel Crushing rubbles(10) STOP OPERATION WHEN MACHINE BECOMES ABNORMAL, Stop operating the machine immediately if some part is damaged or strange noise or other trouble happens during operation, Continuous operation of the machine without repairing it can cause more serious breakdown and accidents. Check the cause of the trouble immediately and repair or adjust it to prevent breakdown. If hydraulic oil leaks from the machine or the hydraulic hose during operation, stop the operation and shut off the engine immediately. Check and repair of the oil leakage.3. After operation () Precaution for parking Park the excavator on flat and firm ground. Lower the hammer on the ground. Before leaving the machine, stop the engine and take the key out to prevent unauthorized person from operating the machine, If it is unavoidable to park the machine on an inclined ground, take a necessary messure such as block up the crawlers to prevent the excavator from moving unexpectedly. Lower the hammer on the ground and put all control levers in the neutral position, and then block up both lower side of crawlers. Lock the swing as well, ‘When parking the excavator on the road, fence the excavator and put a sign which can be recognized even in the dark, to prevent an accident. Lower the hammer on the ground and lock the door of the operator’s cabin to prevent unauthorized personnel from operating the excavator. When leaving the operator’ seat take necessary measures to prevent an accident, Refer to instruction manual of excavator provided manufacturer for the procedures when leaving the operator’ seat. Followings are major precautions. Park the excavator on flat and firm ground, Lower the hammer on the ground. Put all the control levers in the neutral position. 1 2. 3 4. Fit the safety device (swing lock and contro! lever lock, etc.), 5. Stop the engine and take the key. Keep the key properly. 6 Lock the operator’s cabin and prevent unauthorized personnel trom moving the excavator. “13°(2) REMOVAL AND INSTALLATION OF HYDRAULIC HAMMER Removal and installation of hydraulic hammer at unstable place or sloping area may make the machine unstable, which may cause an accident. It should be done at flat and wide place where is no one surrounded and no obstacle. Removal and installation procedure for the hammer is shown below. 1. To remove the hammer from excavator stick, close the shut off valves and then disconnect the hydraulic hoses from the hammer. 2. Always be sure to seal the shut-off valves, pipe end and hose end, using plugs. As in bucket replacement, replace the hammer with the bucket while the hammer is mounted on the bracket 4, To install the hammer, use the procedure reverse to removal. Shut-off valve Hose Open and close of shut-off valve Caution Use caution when removing or installing the hammer in order to prevent foreign materials such as sand from entering the hose, shut-off valve and pipe. Fitting or removing mounting pins always involve a risk. Never put hands or fingers into the mounting pinhole as excavator arm and hammer may move unexpectedly and hand or fingers may be caught. Follow the cautions below when hammering in the mounting pins. 1. Do not hit too hard, or do not hold the pin by hand, 2. Do not stand at the side from which the pin comes out. It is danger as the pin may jump out or get into the hole suddenly, 3. Always wear a goggle. “ua(8) STORE THE HAMMER SAFELY ‘The hammer is easy to fall down and is very danger if not properly stored. Stabilize the hammer when storing. Do not allow an outsider o chiléren to enter the storage area Proper storage way is shown below. 1. Check to see that the plugs are in place when the hydraulic hammer is not in use. 2. When not in use, keep the hammer where it will not be exposed to the rain. The hammer should be stored indoors, or on crosstie and covered with a canvas sheet 3. Before storing the hammer grease the sliding parts well Retain hydraulic oil In the hoses Cover with a canvas sheet Seal off hose ends Crosstie 4. In case of long-term storage, the piston should be kept with following rust proof procedures. 1. Take off a chisel from the hammer. 2. Discharge nitrogen completely from piston gas chamber through gas charge port in the cylinder cover. 3. Press the piston toward the upper s of cylinder with round bar by hitting slightly and at same time nitrogen gas must be discharged from piston gas chamber, 4, (After finishing procedure 1 to 3) Grease both inside of the chisel holder and on a chisel, and then insert the chisel into the holder Refer to the illustration in next page. “15-Press the piston Toward upper side By hitting slightly4. Inspection and maintenance (1) Understand the inspection and repair method. Failure to follow thi pection and repair instructions may cause not only the damage of the machine but also serious injury or death, Before inspecting or repairing the machine, thoroughly read this manual and fully understand the proper inspection and repair method (including the preparation for safety work, appropriate tools, licenses, required parts, protection gears and so on) and perform the inspection and repair safely (2) Use protective gears Performing the inspection or repair without using protective gears is danger and mey cause injury such as bum, cut, falls, eve damage and so on. When inspecting or repairing the machine, wear the safety glasses, safety helmet, and safety boots. Make sure to wear the protective gears such as face shield, safety glasses and safety helmet when using a grinder or hammering. (8) Use proper tools Performing repair work without using proper tools may cause not only part damage and a n are suitable drop in work efficiency but also serious injury. Use only proper tools wh for work, Using a deformed chisel or hammer is danger as they may chip off the splinters may fly over. (4) Put in order and clean the working area Ifthe work area is disorder, you may be fallen down or injured by the splinters. Remove the obstacle and clean the grease, oil, paint and other debris, and put the working area in order to ensure the safety work. (5) Wash the hammer before inspection and repair Repairing the hammer without washing will not only makes it difficult to discover the troubled point but also may cause an injury. When washing the hammer, wear proper protective gears such as non-slip shoes, goggles, gloves, *** Pay attention to high pressure jet (when use). Do not touch high pressure jet.© 8) Inspect and repair on level ground Inspecting or repairing the machine on an incline makes it difficult to judge the machine condition correctly and the machine may move unexpectedly for its weight, which may cause a serious injury. 1. Perform the inspection or repair only on a firm and level ground for safety. 2. Make sure to lower the hammer on the ground or to support the hammer with the props or wooden blocks. 3. Stop the engine and take the key. 4, Block up the 5. Never work under the hammer unless the hammer is supported securely wlers. Be careful with the high temperature oil and machine During and right after the operation, the temperature of the ofl becomes very high and touching the high temperature hydraulic ofl may cause serious injury, Replace the hoses after the temperature of the hydraulic oll cools down. Right after the oper tion, the hammer, chisel, excavator are still very high temperature too and contacting them may cause a serious injury. Make sure to start the inspection or repair work after temperature of them cool down. Beware of high pressure oil Do not touch the hydraulic hose which is pressurized internally as the hydraulic hose may burst and high pressure hydraulic oil may spout out. The high pressure hydraulic oil may cause serious injaty or death if it gets into skin or eyes. Follow the precautions belovr 1. Do not touch the hydraulic pressurized hose. 2. Release the residual hydraulic pressure before connecting or disconnecting the hydraulic hose. Hydraulic oil leakage from a pin hole is sometimes invisible. Use a piece of cardboard or wooden board to check oil leakage. Never use your bare hand. 4, Wear safety goggles to protect your eyes. 5. hydraulic oil get into ski, have an emergency medical treatment immediately. “18°@) Release the residual pressure before repair If @ part fitted in the hydraulic system, such as plug, hydraulic hose, pipes, and filter, is removed without releasing the residual hydraulic pressure, the hydraulic oil will spout out. Shut off the stop valves and start the inspection or repair work after the temperature the hydraulic oil cools down. Refer to the operation manual of the excavator for the procedure to release the residual pressure. (10) Beware of splinters when hammering (1) Release the gas before disassembling the hammer Hammering hard steel parts such as pins, bushings and chisel involves risk of injury as the splinters may get into an eye, When hammering, wear safety glasses and safety helmet and place a brass bar between the object and hammer. ‘As the splinters may fly out, make sure that there is no one around before start hammering. If disassembling the hammer without releasing the gas charged in the piston gas chamber in the cylinder cover, the parts mey blow up and cause serious injuries due to expansion pressure of the gas. Be sure to release the gas according to this manual before disassembling the hammer. When releasing the gas from the gas chamber, blowing gas and dusts may hurt your eyes. Wear the safety goggles and do not close up your eyes to the gas vale. (12) Use only nitrogen gas (a3) aa Using a gas other than nitrogen gas is danger and may cause an explosion. Be sure to use only nitrogen gas when charging the gas chamber. Precautions for handling the accumulator (High pressure accumulator is installed in the MKB1800V and above ) The accumulator is charged with high pressure gas and an explosion of the accumulator may cause serious injuries or death, Never disassemble the accumulator. Ifthe accumulator becomes malfunction, replace it with new one. Keep fire away and don’t give shock to the accumulator. Precautions for handling the nitrogen gas cylinder ‘The nitrogen gas cylinder contains very high pressure gas and explosion may cause serious injuries or death. Keep fire away and don’t give shock to the nitrogen gas cylinder. Keep the temperature of the gas cylinder below 40°C. “19°(15) Check the bolts and nuts before charging the gas Ifthe ges chamber is charged with the gas without firmly fixing the cylinder cover with the bolts and nuts, the cylinder cover may blow up and cause serious injuries due to the expansion pressure of the gas. Make sure that cylinder cover is fixed firmly before charging the gas. (16) Be careful with the swing of gas hose When charging the gas into the gas chamber, the gas hose may swing severely, which may cause injuries. Hold the gas hose firmly when charging the gas. (17) Be careful with chisel when charging the gas, When charging the gas into the gas chamber, the piston may strike the chisel and the chisel may jump out. Without the chisel holder pin, the chisel may jump out unexpectedly. Before charging the gas, make sure that the holder pins are fitted, Also be sure that there is no one in the direction of the chisel even if the chisel jumps out. (18) Be careful with the bolts when cutting When gas-cutting the bolt which compresses a spring or rubber, the bolt may jump out and this may cause injuries. Be careful with the jumping bolts. When cutting the bolt with gas torch, the hammer may also be heated up and the hydraulic oi! may spout out and may catch fire. Heating up the hammer exerts a bad influence on strength of heated hammer part. Never heat up the hammer directly. (19) Do not heated up the hydraulic equipment and piping When heating up the area near the hydraulic equipment and piping by welding, inflommable steam or mist may be generated and they may catch fire. Do not perform welding, soldering, and heating by gas torch around the area near the hydraulic equipment and piping. Pressurized pipe and rubber hose may break suddenly if they are heated directly. Cover them with fireproof sheet.(20) Precautions for welding works During repairing the machine by welding, breakage of electrical equipment end burning paint may generate gas and this may cause fire. The welding work must be done in a well-equipped place by a qualified welder. Following are the major precautions when performing welding work, 1. Remove the battery terminals of the excavator to prevent electric contral devices from being damaged or malfunctioning. 2. Remove the battery to prevent explosion when welding location is close to the battery. 3. Remove the paint from the welding location to prevent gas generation, Remove the electric parts to prevent malfunction of the excavator. 5. Connect the ground wire at the location within 1 meter from the welding location. Connect the ground wire so that there is no seal and bearing between the ground wire and the welding spot. 6. Wear the necessary protective gears. 7. Ventilate well in the welding area. 8. Put inflammables away and prepare a fire extinguisher. (21) Do not use deteriorated hydraulic hose Fetigued, deteriorated or damaged hydraulic hose may burst and high pressure oil may gush out. Ifthe hydraulic hose bursts, the hydraulic oil gushed out may get into human body causing serious injuries or death. The hydraulic hoses which move during operation are fatigued early. Replace them at an early stage. (22) Check the machine after repair Operating the machine without repairing the abnormality will not only lead to major damage of the machine but also cause an accident or serious injuries, Check the source of abnormality immediately, and adjust or repair it to prevent any accident. Check the machine following below after repair. 1. Operate the machine at low engine speed and check that there is no oil or water leakage from the repaired location. 2. Move the control lever slowly and check their functions. Then increase the engine speed and check once again that there is no abnormality. 3. Operate the hammer with regular engine spoed and check the hammer that there is no abnormality in the operation, “ae(28) Do not modify the hammer (24) (25) Modifying the hammer will not only decrease in the performance and service life but also the hammer. Consult the seller if the hammer is used for spoil the safety, Do not mo: a special application Disposal the waste oil Dumping the waste oil causes environmental pollution. Never dump the waste oil on the ground, river, and swamp. When the waste oil is drained from the machine, use a vessel to collect it. Follow the regulations of the authorities to dispose the waste oil, fuel, cooling water, coolants, brake fluid, solvents, filters, batteries, hoses and other toxic waste, Consult the dealer with machine trouble Do not perform a difficult repair without having knowledge necessary for such repair as it vill lead to further damage of the machine. Follow this manual and ask its dealer for repair if necessary.5. Daily inspection (1) When hammering, check periodically to see that the hammering force, rate of blows, hose movement, and hydraulic oil temperature ( below 80°C) are normal. (2) Check for oil leakage in the hammer, and ascertain that no bolts and hose connectors are loose. Should any oi] Jeakage and/or any jose bolts be detected, replace the packing and/or tighten the bolts, or hose connectors. Proper tightening the hose connectors Use caution not to twist any of the hoses when tightening the hose connectors. Hold the hexagon head of the hose connector and turn the union nut of the connector. Use proper spanners. (3) Check the oil filter of the excavator at reasonable intervals for possible contamination of the hydraulic oi Replace the oil filter every 100 hours of operation. The hydraulic oil should be change ‘every 600 hours of operation. (A) Replace either the holder and stopper bushing or the chisel, if the clearance between them is over that specified or more. ( Refer to paragraph 9.3 in part 2) IF the chisel diameter wears down more than thet specified, replace it. Replace the holder bushing if it wears down more than that specified in diameter. (Replace the stopper bushing also when the holder bushing is replaced.) Never forget greasing before starting and every 2 service hours. (5) Check the gas pressure inside the piston gas chamber. If itis lower than that specified, fil the gas chamber with nitrogen gas. To measure the gas pressure, remove the cap from the gas charge port, and fit the adapter with the pressure gauge into the port. ‘The gas pressure can be read on the scale of the gauge.WARNING Use only nitrogen gas for filling purposes. Use of substitution such as air or oxygen will create the danger of an explosion. Always handle the gas cylinder carefully. Nitrogen gas charging procedure 1.Connect the regulator and the hose to the nitrogen gas cylinder. Fit the handle lightly onto the regulator. 2.Remove the adapter cap from the gas charging port of the piston gas chamber and attach the hose to this port. Then open the valve of the nitrogen gas cylinder. 3,Turn the handle of the regulator and adjust the pressure up to the required level. 4.After charging with nitrogen gas (approx. 10 seconds), close the valve of nitrogen gas cylinder and disconnect the hose from the gas charging port, 5.Finally, fit the pressure gauge to the gas charging port to check the gas pressure inside the gas chamber. Regulator Pressure gauge? (including adapter & O-ring) Gas charge Port Nitrogen gas cylinder jed to have spare chisels, holder pins, packing, and bolts. It is recommen As mentioned chisels, holder pins, packing, ofl holder and stopper bushing: and grease are consumable items.PART2 INSPECTION AND REPAIRS 1. HYDRAULIC HAMMER DIMENSIONAL DRAWING 460 Gara eereey 205 200 145 | foyu t 11 | 2 3 Hose connection vor + AR A Pekigh pressure : Tilow pressure 4 g : ~seriat No. Da Dj} a 1 gj gf beso a gl a : ie + | jj wetcaeotn 18 300 — + +290 4 L e150 33. es a44 aa eueecieeea2, HYDRAULIC HAMMER CROSS SECTIONAL DRAWING 60 126 60 12060PART LIST 0B632050 0891233 HEXAGON SOCKET BOL? INJECTION VALVE BODY KEYNO. | PARTNO- PART NAME. x REMARK, i /OBo2101F ‘CYLINDER Une.NO. 69) 2 | OB92102 CYLINDER COVER 3 | OBS2103 HAMMER PISTON 4 |OB92104rG CHISEL HOLDER _5___|OB912050 HOLDER BU: cE 6 |0B91206FG | STOPPER BUSHING 8 — | OB91208C HOLDER PIN 10 | OB813020 RUBBER PLUG 1 /OB9sa5, STOPPER PIN 12__|OBsi02 GREASE NIPPLE 13 [OB8137 ‘CLAMPING PIN 16 |OB921168 EAL BUSHING 17__|oB92117 RING. 18 /OB92118 ‘SLIDE RING PACKING 19 |OB9i219F O-RING 20 |OB5941500 BUFFER RING OB91229F [DUST SEAL OBS412 [GASKET ann oe (08912498 085307 OB5402 OBos34B INJECTION VALVE PISTON OB8280 [CAP ‘OBSI131 TRING | 085353 O-RING OB5352 O-RING 085430 GASKET | | OB511N1560__| O-RING. | | ‘OB6120135R | HEXAGON BOLT BEp ee af eo lnc ae tole ale ew to IS 52__|Ono1252 PLAIN WASHER, 06839 HELICAL COIL C oR5185 O-RING 08561500 U-RIN ;ou 08571500 BACK-UP-RING {4 Op92i6s | TIE BOLT i ae ce OB91266FHH | HEXAGON NUT (ine.NO.70) a] OB91267FHH | NUT (IneNO.70) a | OB91269F PLAIN WASHER 4 OB6s29 HELICAL COIL. ® OB8319 RETAINING RING 1 OBS318 BALL 1 (0B93086 AIR INHALATION VALVE BODY 1 ‘0B92087 ‘SPRING HOLDER 1 opg208s SPRING ee | PHEEEEEHEEE OB9zis FE CHISEL HOLDER UNIT Une. NO.4~6.89,11~1 | (1 oB93092 AIR INHALATION BALVE KIT(me.NO.75~79) |) | OB92193B SEAL BUSHING KIT (fnc.NO.16~ 19, 60,126) @ | OB91794CN [HAMMER CONTROL VALVE UNIT 1 SEE NEXT PAGE OB91295 INJECTION VALVE KIT (Ine.NO.33~39) w [OB84 10265 ‘SEAL 1 OB3481 PRUG 7 OB36058KK1 | PRUG KIT 3 0B5487 BACK-UP-RING 2 |HAMMER CONTROL VALVEUNIT OB91794CN SECTION ABCD PARTS LIST KEY No. PART No. PART NAME QTY | REMARK i He HAMMER CONTROL VALVE UNIT aot tee 94 | OB9IT9ICN 1 (inc.NO. 31,53~57,72,82) 23 | OB91723CN | CONTROL VALVE HOUSING (Inc.NO.58) | (1) | 24 | 0B91724 | CONTROL VALVE COVER w 25 | 0B91725B_ | CONTROL VALVE PISTON w 26 OBS165GH O-RING (3) 27 OB6361 HEXAGON SOCEK BOLT 6) 28 OBS410 GASKET (2) 29 OBS411 GASKET w@ 30 OB5444 GASKET (2) 31 OB5412 GASKET @ 53 OB91253 RESTRICTOR VALVE HOUSING a) 54 | OBS321 O-RING, @ 55 OB91255 RESTRICTOR PISTON a) 56 OB6661 HEXAGON NUT (1) 57 | OBS213. | O-RING w 58 OB6815, HERICAL COIL. ©) 72 OB5438 GASKET (2) 82__ | 088302-M42 | POLYCAP ®MEMO “29°3.BRACKET INSTALLATION SKECHPARTS LIST BRACKET BUSHING in next page KEY NO. PART NO. PART NAME aT ‘SPECIFICATION i OBO210VHITB. BRACKET, 1 2 | oBo80009 COVER 2 3___[ OBORO009A. COVER 2 4 [08080153 COVER. 1 5 | oBosoi4i COVER, i 6 | 08080208 PLATE 2 7__|opsi0175, ‘CUSHION RUBBER 1 | 290x290x030 @__ | 08810026 ‘CUSHION RUBBER 3_| 280x160xt35, 9 | 0B810025 ‘CUSHION RUBBER 4 | 280x160x120 10 | OB8100254. ‘CUSHION RUBBER. 1 | 280x160x120 11__| 0B810034 CUSHION RUBBER. 2 | 250x125x150 12 | OBB10176A4. ‘CUSHION RUBBER 1_| 230x125x160 13 | OB810177 ‘CUSHION RUBBER 1 | 270x145xt35 id | OB8491A ‘CUSHION RUBBER 1 | 300x300xt50 15__| 08810179 ‘CUSHION RUBBER 2 | 250x125xt45 16 | OBG124045 HEXAGON BOLT. 24 | M24x3x45 17 | 08632030 HEXAGON SOCKET BOLT. 6 | M20x2.5x30 18__| OBG330060 HEXAGON SOCKET BOLT. G_[M30x3.5x60, 19 | OBGI24110B HEXAGON SOCKET BOLT. 4 | Madx3x110 20__| OR662240 HEXAGON NUT 4 [Mads 21__| OB67520A LOCK WASHER 12_| M20 22_| 0B67524 LOCK WASHER. 48 | M24 23 | OB67530 LOCK WASHER 12_[ M30 24 | OB3485 PLUG. 2 [RI 25 | OBSTIBA. SEAL. 2 26 OB61160708 HEXAGON BOLT 2 | Miéx2x70 27 | OBET6L ‘SPRING WASHER 2 | MI6 26 | OB080216 SHIM 2 | 307x30Tx2.3 32__| OB6281 HEXAGON BOLT 2__| M20x2.5x220 33__ | OB6527 HEXAGON BOLT 8 | M30x3.5x80 34 | OB6130110 HEXAGON BOLT 4 | M30x3.5x110 35 | OB6671 HEXAGON NUT 41 M20x2.5 36__ | OB6694 HEXAGON NUT. 47 M30x3.5 37__ | OB6791 SPRING WASHER 12 | M30 30__| OBoZ50VP3 CONNECTION PART. 1_|Select suitable one BRACKET PIN 2_ | according to the table 4 4 SPACER “31List of excavator-hammer connecting parts oie or ae Suitable Rammer part Width of Stick | BRACKET PIN BRACKET BUSHING] SPACER Pin diameter | __ PART No. PART No, PART No, Gene a (08039080-N 0804901381 | 0805901751 7 Sonn Sel | 0B038080-N opos9o13e1 | oposgotsat 7 Maida 7 oan ©B031080-N 0804101391 | 0805102131 fee a (08031 180-N 0804111391 | oB05112131 a Seal C : : a Boseo80-N OBodsorae: | oBnst0z132 [eiees . aL ) opcaiaso-Nn oposioise: | oBostoata2 7 ceeetaa | _980eto8o-N | oBoatotoat | oB0s102021 ered: (0803118001 OB04111391 | 0605112111 | See: eal 0B031080—N oB04101391 | 08051320114. CHISELS Only chisels manufactured exclusively for use with this MKB Hydraulic Hammer should be employed. The seller does not warrant the performance of any part of the machine if chisels other than those are used, POINT CHISEL OB9ZI7IGA AS FLAT CHISEL, opg2172 FLAT-END CHISEL — OB92173 5. PIPING ACCESSORIES To operate the hydraulic hammer, install the hammer piping onto the excavator front attachment. Connect both the high-pressure and low-pressure lines of the hydraulic piping to the hammer. The working high-pressure level ranges ftom 15 to 18 MPa (153tol84kef/cm’), and the rate of oil flow at this time should be 135~180.I/min A relief valve may also be required, depending on the model of excavator. The equipment to be added for the piping differs according to the model of the excavator. Refer to the piping instruction diagram attached to the piping materials for details on the equipment for piping.{TYPICAL PIPING DIAGRAM] Hanmer Operation pedal Hydraulic Hamer / Selector Valve a” Relief Valve i) + 1! ELIS ° I] | t ~ Shut-off valve b= ?6, TOOLS (OB70212HN2) ‘The followings are the standard tools for hydraulic hammer PARTNO. [PART NAME Sizs_[QTY|__PURP B7101___ | TOOL BOX 1 ce [op6ss2 | EYEBOLT Mio [1 (Holder pin oB7zi9 [SPANNER 19 2 | Shut-off valve OB7224 | SPANNER 24 1 | Cushion Rubber 0B7230 —_ |SPANNER 30 2 | Hexagon nut for bracket 0B7236___|SPANNER _36__| 1 |Tie bolt OB7241 SPAN! AL 2 | Hose 0B7246 [SPANNER 46 1 [Bracket oB7324 | WRENCH 24 1 | Gas injection valve OB7346 WRENCH AG 1 |Connection part }OB7350 WRENCH 50 1_|Hose (OB7408—_ [SCREW KEY 8 1 |Restrictor valve loB7414. [SCREW rr 1 | Accumulator OBT417 SCREW KEY 1 1 |Control valve cover OB7419 SCREW KEY 19 1 | Tie bolt 0B7422__| SCREW KEY 22 1 ‘0B75001 | WRENCH 65 1 |e bolt OBT7507 WRENCH 30, 1 {Accumulator |OB7534 BAR 20x 260) 1 |Lock pin OBG402 EYEBOLT M20_| 27, GAS CHARGING EQUIPMENT AND GAS PRESSURE ‘The following equipment is necessary to charge the piston gas chamber with nitrogen gas and to check the gas pressure inside this chamber. Refer to page 23~24 for the instruction on nitrogen ges and checking. When inspecting the pressure, keep the hydraulic hammer chisel level egainst the ground Gas pressure is variable in accordance with the hammer temperature (oil temperature) So you may check the gas pressure referring the table below. GAS CHARGING EQUIPMENT (0B91297T) KEY NO. | PART NO. PART NAME, QTY | REMARK 1 (0B8302 |” NITROGEN GAS CYLINDER [1 2 op2521 | REGULATOR 1 3 081733 | HOSE 1 4 0B3686 | ADAPTER 2 5 OB5104 | O-RING 2 6 082808 | PRESSURE GAUGE 1 7 B3440_| ELBOW 1 Table of gas pressure Hammer body temperature (°C) |15 ~ 25/25 ~ 35/35 ~ 45/45 ~ 55/55 ~ 80 Setting gas pressure (MPa)| 0.7 o73 | 075 | 078 0.85 Setting gas pressure (kef/om?)| 7.1 14 Wd 8.0 87 When the gas pressure rises over specified range according to rising of the hammer temperature (ofl temperature) , please adjust it within specified range. “36°8. OPERATING PRINCPLE ‘The hammer piston moves up and down when the reverse chamber (C4) at the middle area is linked alternately to the high and low ~pressure lines in keoping with the reciprocating motion of the hammer control valve piston, UPWARD STROKE ( LONG STROKE ) 1. When the hammer pedal is operated, the high-pressure oil flow: 10 chamber Cl, then ‘the hammer piston moves up, compressing the nitrogen gas in chamber C5. The control valve piston is shifted downward because of working high-pressure in chamber C8. 2. When the high-pressure oil flows into chamber C3 after the hammer piston has reached the end of the upward stroke, chamber C7 becomes high-pressure. ‘Tho control valve piston begins to move upward because of the different pressure receiving area between C6 and C7. (C7 > C6) DOWNWARD STROKE 3. When the control valve piston moves upward, the high-pressure oil flows into chamber ca, ‘The combined hydraulic and compressed nitrogen gas pressure forces the hammer piston to begin moving powerfully downward. 4, When the hammer piston moves down and strikes the chisel, chamber C3 as well as chamber C7 is in a low-pressure condition. As a result, the control valve piston begins moving downward because of the pressure in chamber C6. ++es+The series of operations mentioned above are repeated so that the hydraulic hammer operates continuously.+ UPWARD STROKE ( SHORT STROKE ) ‘When the stroke adjust valve rod is shifted upward, the chamber C2 in the cylinder leads to ‘the chamber C7. As a result, the high-pressure oil lows into chamber C7 after the hemmer piston has reached the chamber C2. Then the control piston begins to move upward. As described above, the hammer piston begins to move downward after it has reached chamber C2. Therefore the number of hammer blows increases but percussive force decreases according to the ratio of stroke length between long stroke percussion and short stroke percussion. “31UPKARD STROKE @ DOWNWARD STROKE contra! piston uP He Hammer piston chiset a a 8 ca Pe | Bt ys at is @ & 1H ry] & Piston higrpressure cenber Pilot chenbert3 : Piston reverse chanher Piston gas chenber Hamer control. valve piston high-pressure chanber Hamer control valve pisten chenber + Hamer control valve pllot chanber High-pressure off Line Lowpressure oil Line “38 @UPWARD STROKE ( SHORT STROKE) HYDRAULIC CIRCUIT DIAGRAM eo a oe Ho Le <_HP Ga Stroke adsust Lad valve rod ir 39°9. MAINTENANCE AND INSPECTION 9.1 Bolts ‘The bolts used with this hydraulic hammer tend to become loose since they are always exposed to intensive vibrations during operation. It is therefore essential to check as frequently as possible the tightness of the bolts and to see whether or not any is missing, an excessive strain be place on the remaining bolts, thus subjecting the hammer to be possible breakdown. If any bolt is discovered to be loose or missing, they should be tightened or replaced as soon as possible, Should the bolts become loose frequently, contact the service shop. ‘The torques applicable to the various bolts are shown in the table below. APPLICABLE 1 REY part NAME |PART FOR USE SIZE TORQUE REMARK NO I (eam) Nem thf : For iataling the oyinden, 65 |r nour 66 [HEXAGON NUP areal ‘cover and chisel 65 4200 {3100} M45x3- zg [HEXAGON SOCKET [Forinstaling the bommer | qq! 5 : 73 Trout |control valve housing Gkey)17 510 (350) M20x2.5 yy [HEXAGON SOCKET — [Por locking the hammer | 27 JRour ontral valve housing cover |%*14] 260192} | Mi6x2 gp INJECTION VALVE : | 33 lpopy 24 49 136.0 MI8x1L.5, 12 |GREASE NIPPLE 10 12.7 {9.4 RUS 53. |RESTRICTOR \Wor restrictor valve housing | 36 450 {330} | M30x1.5 | 56 [HEXAGON NUP Forlocking the estritor | 4g | navtog | Muoxe |HEXAGON SOCKET |For plugging the hammer | ST Inu |control valve housing Grey) bots NPTRLAG 4s [HEXAGON pour ——_[Foranstaling tho | 90) s90t@em | aa0.25 EBXAGONSOCKET —fFortskingapartthe | gy), 7 49 |poLr Lebietiaeinie key)id 240 {177} MI8x1.5, Teexacow wer [Forlecking he hammer | gy | goog fargo) | nena : zt | seta | sees HEXAGON NUT Forboltsofbracket ine | 2% | 206 (45) | Misaz IscreweD exp Hose [PerByirwuieot sspolvamt] 59 | gro nage) | tape18 HOSE CONNECTOR — [For 25mmq (1B) hose a as7aop | Gt HEXAGON NUT Fitmesbomangeonsatansteg [aE g 49tsc) | Miox15 eal besauoai |For shut-off valve (key)3 1.96.44) | M4x0,79.2 Piston gas pressure ‘The hammering energy of the hydraulic hammer is produced with the force of the hydraulic pressure plus the force of the gas pressure of the piston gas chamber. ‘The gas pressure ranges from 0.7 to 0.85 MPa ( 7.1 to 8.7 kef/om’). If the gas pressure is increased beyond this range, the hammer may not operate; if the pressure drops below the specified rango, the oil flow rate becomes insufficient. Consequently it will cause decrease of the hammoring energy and swing of the hose. ‘The gas pressure varies with the temperature and working conditions of chisel used. It is therefore necessary to koop the gas pressure within the range specified during operation. Should the gas pressure be lower than that specified, charge with nitrogen gas, Check X-ring (17) whenever required, Check the gas valve with soapy water. Ifat the time of disassembly hydraulic oil is discovered to have leaked out into the piston gas chamber, replace the slider ring packing (18), O-ring (19, 60), back-up-ring (64,100). At the same time, check that there is no scoring or flaws on the sliding part of the hammer piston. Always use nitrogen gas for the piston gas chamber. Do not use air or oxygen as there is the danger of explosion.9.3 Chisel and holder bushing When the clearance between the chisel and the holder bushing becomes too great, the hammer piston will contact the chisel irregularly, and the hammer piston and chisel will be susceptible to damage. In case the clearance is over 9 mm at a point 20 mm from the front end of the holder bushing, replace the bushing and/or chisel with another. ; if the holder bushing wears down over § mm in diameter, replace the holder bushing and the stopper When the chisel diameter is worn more than 4 mm, replace the chi bushing with anther ones. For the replacement of the holder bushing, contact to the service shop. Clearance measuring for Chisel and Holder bushing Point recessed 20mm inward Chisel holder 9.4 Working pressure ‘The working pressure of MKB2100V ranges from 15 to 18 MPa(L53to184kgf/cm®). If the discharge pressure of the hydraulic excavator is over 18 MPa (184kgt/em*) , it is necessary to install a relief valve in the high pressure line of the hammer so as to set the working pressure. Ask the service shop to set the working pressure. Should the working pressure be set beyond 18 MPa(184ksf/em’) the shocks from the hammer become intensive, subjecting both the hammer and the excavator to damage.9.5 Oil temperature ‘The temperature of the hydraulic off changes with surrounding temperature and/or working conditions. But normally it ranges from 50 to 80°C. Should the oil temperature exceed 80°C, the seal packing will be impaired and their service lif will be shortened. Note the following suggestion in order to prevent the oil temperature from rising. (1) Never hammer at the same point for more than 1 minute, (2) Operate the hammer at the proper engine speed. With this hammer, the required oil flow rate within a working pressure range is constant. Therefore, even if the engine is run up, neither the hammering energy nor tho rato of blows increase. In addition, oil will leak out from the relief valve, resulting in a rise of the oil temperature. Consequently the rate of fuel consumption is increased. ( Recommended engine speed } If the engine speed is gradually accelerated while the hammer is in operation, the ‘working pressure increases elong with the engine speed but it ceases after the engine spoed has reached a certain limit. The hammer should therefore be operated at this top effective engine speed. (3) Keep the radiating surface of the cooling fins clean, otherwise the cooling efficiency will be reduced. 9.6 Oil leakage Chock the hydraulic hammer for oil leakage. Normally, a very slight amount of oil should leak out on the chisel holder and chisel, serving to lubricate the chisel. If oil leakage is detected, locate the oil leak and then replace the O-ring, packing, etc. Apply a small of hydraulic oil to the slide ring packing (18, 20), O-ring (19,21) , X-ring (17), dust seal (22), U-ring (61) , back~up-ring ( 62 ) and packing groove. For other O-ring, the application of grease (silicon grease is recommended) will be effective in the prevention of oil leakage. “ Note the following when any packing are replaced.” “43°1. Check to see that there is no scoring or flaw on the surface of the sliding part on which the O-ring or other packing are fitted. Check to see that there enough pressing clearance for each of the packing. Check to see that the packing edges do not protrude beyond their set positions. Handle the O-rings and other packing with care to prevent dust and other materials from slipping into the hammer, Care must also be directed to avoiding scratches and other damages. If the slide ring packing is discovered to have been damaged, make the following checks in addition to inspecting the damaged part of the packing. Check to see whether or not the surface of the sliding part of the hammer piston is damaged. Chock to see whether or not the dust seal ( 22 ) protrudes out beyond the set position and the cylinder bushing wall. Check for any damago on the cylinder wall and the cylinder bushing well. Iftoo much ofl leaks out onto the chisel or the chisel holder, this indicates that the U-ring (76 ) and slide ring packing (20 ) are damaged, necessitating replacement. When replacing the above, the back-up-ring ( 62 ) and O-ring ( 21 ) should also be replaced. Ask the service shop for replacement of the sliding packing.9.7 Chisel and holder pin If there is a deficiency in the pressing force during hammering, or if the material subject to hammering is breakable, the chisel and holder pin will hit each other. Consequently, these parts will become deformed, causing laps on its surface. If such laps are detected during check, remove them by using a grinder or sander. Replace holder pin, depending on its condition. Remove laps, using grinder 9.8 Contamination of hydraulic off Ifthe hammer is operated with contaminated oll, the hammer control valve will be subject, to malfunctions and the hammer piston may become scored. Always keep the oil clean. For this purpose, replace the filter element of the hydraulic excavator every 100 hours of operation, and replace the hydraulic oil with a new supply every 600 hours of operation. Prior to mounting the hammer to the stick (arm ) of an old excavator, replace the hydraulic oil with new one. Further, any shortage of oil should be replenished with required amount of new oil 9.9 Accumulator When the hose used for the high-pressure linen swings abnormally, check the accumulator (49). If it is malfunction, replace it with new one. When replacing the accumulator, replace the O-ring (60,47) and back-up-ring (61) too. In addition, when replacing the accumulator, check to see that the oil inlet/outlet at the bottom of zecumulator is not damaged Hexagon bolts (48) should be tightened according to the specified torque as mention on. 9.1.In addition, bolts should be tightened little by little diagonally.Memo “46°10. DISASSEMBLY AND ASSEMBLY Matters that require attention on disassembling and assembling the Hydraulic Hammer: 1. First refer to all paragraphs regarding the process for “Disassembly and Assembly “ so that the hammer (including bracket) may be disassembled and assembled with ease. 2, Dust and other foreign materials are one of the worst enemies the hammer has. Always assemble and disassemble the hammer in clean surroundings, 3. It is requested to use MKB genuine parts when any part of the hammer is to be replaced,10.2 Disassembling the bracket When disassembling the bracket, loose the hexagon bolts (14), hexagon socket bolts (18),and remove the cover ( 2,3,), and cushion rubber (9,10,13,). After that, remove the chisel following the procedures in page 10. ‘Then stand the hammer securely. ( Never start working unless the hammer is supported securely. ) (1) Loosen the hexagon nuts (18), and loosen and remove the hexagon socket bolts (17 ) ‘Then remove cover (4), cushion rubber ( 11). After that, loosen and remove the hexagon socket bolts ( 16), and remove the plates (6). (2) Loosen and remove the hexagon nuts ( 30 ), and remove the spring washers ( 29), (3) Remove the connection part (31) using a hoist and wire. (@) Insert the eyebolt ( M20) into the service hole on the head of the cylinder cover. (6) Lift out the hammer body, and place the hammer on crossties horizontally. Then lay the bracket ( 1) in the same way. Remove the cushion rubbers ( 6,7 and,8) 10.3 Assembling the bracket The bracket is assembled in the reverse order of that described for disassembly paragraph 10. Before assemble the bracket, wash and clean the bracket and check the inside of the bracket that there is no obstacle to fit the cushion rubbers and insert the hammer body. ‘The hexagon bolts (15,17 ) and nuts ( 30 ) should be tightened according to the specified torque as mentioned on 9.1. ‘The bolts and nuts should be tightened little by little diagonally. Notes on assembling the bracket: ‘The hydraulic hammer body is supported by the cushion rubbers in the bracket. So it is important to use non~injured cushion rubbers. Replace the Place the cushion rubbers on proper position, and fix them on each position using an jured cushion rubbers. adhesive agent. “4910.5 Disassembling the hydraulic hammer () * Removal of the hammer piston (3 ) * Replacement of the slide ring packing (18 ), O-ring ( 19 and 60 ) and X-ring (17 ). (On seal bushing side) 1, Remove the cap ( 35 ) from the gas charge port and push the injection valve piston (34) (with a clean bar having a diamoter of approximately 3 mm ) to discharge all gas from the piston gas chamber. Loosen and remove the hexagon nut ( 66 ). 3. Remove the cylinder cover ( 2). Insert the eyebolt (M 20 ) into the service hole on the head of the hammer piston (3) and pull out the piston from the cylinder ( 1 ) while assembled in seal bushing kit ( 16 ~19 and 60,64,100 ). 5. Remove the seal bushing kit (16 ~ 19 and 60,64,100 ) from the piston (3 ). 6. Take off the slide ring packing (18 ), O-ring (19), X-ring ( 17 ), back~up-ring (126) and O-ring ( 60) ( On seal bushing side ) from the seal bushing ( 16 ). (@) * Dismounting of the cylinder (1 ). % Replacement of the slide ring packing ( 20 ), O-ring ( 21), U-ring ( 61 ), back-up-ring ( 62 ) and dust seal ( 22 ). (At the cylinder bushing) 1, Remove the cylinder cover ( 2.) according to the order described in step 1 ~ 3 of the previous paragraph. 2, Dismount the eylinder (1 ), 3. Insert the eyebolt (M 20 ) into the service hole on the head of the hammer piston (3 ) and pull out the piston from the cylinder (1 ) while assembled in seal bushing kit (16 ~ 19 and 60,126 ). 4, Remove the slide ring packing ( 20), O-ring (21 ), U-ring (61 ), back-up-ring ( 62 ) and dust seal (22). (3) * Dismounting the hammer control valve unit (94 ) and control valve piston ( 25 ). L. Loosen and remove the hexagon socket bolts ( 32 ). 2. Dismount the hammer control valve unit ( 94 ) from the cylinder ( 1 ). 3. Loosen the hexagon socket bolts ( 27 ) and remove them from the control valve housing ( 23 ). 4. Remove the control valve cover ( 24 ). The coutrol valve piston (25 ) is inside this housing ; therefore, an excessively large force should not be applied in removing the control valve cover; tum it gradually with enough force to remove it. “51-5, Remove the control valve piston ( 25 ) (4) * Disassembling the restrictor valve 1, Loosen and remove the hexagon nuts ( 56 ). 2, Take out the restrictor valve housing from the control valve housing (23 ). 3. Take off the restrictor valve piston (55 ) from the restrictor valve housing ( 53 ). () * Disassembling the 1, Loosen the injection valve body ( 33 ) and remove it. 2, Remove the cap ( 35 ) from the injection valve body ( 33 ). 3. Using a screw driver, remove the ring ( 36 ) from the injection valve body ( 33 ). jection valve kit (95 ). 4, Take out the injection valve piston ( 34 ) from the injection valve body ( 33 ). ©) * Disassembling the accumulator (49), 1. Loosen and remove the hexagon bolts ( 48). 2. Remove the accumulator (49) from the cylinder (1). 3. Take off the O-ring (50,47), back-up-ring (51 ). “5210.6 Assembling the hydraulic hammer * The hydraulic hammer is assembled in reverse procedures described in paragraph 10.5. Keep the hammer components freo of dust and other foreign materials during assembly. Check the parts for any flaws, Be sure to fit the packing and bolts snusly. * Apply 2 small amount of hydraulic ofl to the interior of the piston gas chamber. Also apply hydraulic oil sliding parts for the hammer piston (3 ), the control valve piston (25 ), the injection piston ( 34 ), as well as to X-ring ( 17 ), U-ring (61 ), back-up-ring ( 62 ), slide ring packing ( 18 ,20 ), O-ring ( 19,21 ), dust seal (22) and packing grooves. In addition to the above, it is recommended that grease (silicon ) be applied to other O-rings. Note to keep correct position when the back-up-ring ( 62 ) is fitted to the U-ring ( 61 ). (Refer to a figure shown below.) * Mount the hammer control valve unit ( 94) to the cylinder ( 1 ), so that the control valve cover ( 24 ) of the hammer control valve unit ( 94) may be positioned to the upper side of the cylinder. ‘After assembling the hammer control valve unit, check the control piston thet it can move smoothly. * When the hydraulic hammer has been assembled, dismount the injection valve kit (95 ) from the cylinder cover (2 ), and pour 100ce fresh hydraulic oil from the hole and then reassemble the injection valve kit to the cylinder cover. After that, charge nitrogen gas into the piston gas chamber. Caution on fitting the back-up-ring ( 62 ) to the U-ring (61) U-ring(61> Refer to paragraph 9.1 illustrating the torques for the fitting of bolts and nuts. All bolts and nuts should be tightened little by little diagonally,11. Troubleshooting 11.1 Malfunctions Ifthe hydraulic hammer fails to operate, or if the hammering energy and the rate of blows should drop, check the following in the sequence described below after ascertaining that the hammer has been operated correctly. CHECK ITEMS(YMPOMS) ‘CAUSES, 1 | The chisel hammered without a load or is seized, ‘The chisel is notin contact with the stopp bushing ‘€Insulicient grease “The pressure inside the piston gas chamber 2 | fs boyond a rango of 0.7~0.85MP2 (1.1~8.8kef/em0) ‘An excessive amount of nitrogen gas in the piston gos chambor,or gas leakage, “The prossure at the hammer inlet 3 | (high-pressure-lineis lower than the “working pressure. The pressure is not sufficiently boosted,or the quantity of oi is insulicent: “The back pressure at the hammer outlet 4 | (ow-pressure-tineis higher than that specified ‘There is resistance in the return line ‘The resistance of the sliding parts is large. (Check to see that both the hammer piston (Band control valve piston(25)slide smoothly over their full strokes). “€ There is slide resistance, Dust or other foreing materials are caught between each ofthe piston and slideway. The piston have bums caused by trapped foreing materials °* The slide resistence has increased due to other causes, “The chisel dose not mave smoothly. (Chock to soe if the roason,the chisol does not move smoathly,is due to 6 | roughened surface of the chisle, holder pin(8) holder bushing(S), stopper bushing (8)and the chisel hoder(4). ‘he slide resistance of the chisel has increased. ‘The ail ciruit inside the hammer is clogged 7 | (Check the eyiinder{Dand contro vaive honsing(23) ‘There is clogging of the oil cireuit inside hammer “BdeCOUNTERMEASURES REMARKS > Thrust the chisol against the stopper bushing. Rove the burrs or othor icregularities by using a arinder “Abb grease as required, Release or add nitrogen gas in order to att| sain the correct pressure of .7~0.85MPa GA~8.8kt/ em!) IFthe nitrogen gas lesks out frequently,chock the injection vaive,seal bush kit and hammer piston. ‘Check the kydraulic pump,relief and other valves,piping and hoses for any ebnormalities Measure the pressure in the high-pressure line while the hammer is operating and while he hammer is suspended in the alr,whih the pedal put on Be careful so that the pressure guage may be not damaged by hydraulic oft puisation, Check the oll ter piping and hoses. “* Cleaning “#Ropair with an il stone (after using a srinder or a sander to eliminate largo flows) ‘Replacement of parts, there are laws on the slideway of the hemamer piston,check the slide ring packings. the cause of a problem cannot be detected simulre the postitons previously reeched by the hammer and control piston when the hammer filled to work,end review the principle of operation, ‘if both the hammer piston and the control valve piston are dow, there is trouble wth the hemmeer piston “ifthe hammer piston is down and the control valve piston Is up,trouble is occurring with the control valve piston % If the hammer piston is up and the eantrol valve piston is down,the control valve pistion is possibly ‘the source of the problem. ‘both the hainmer piston snd the contre valve piston aro up,there is trouble with the hemar ston, Correct by using a grinder or a sander. Cleaning “5NKB2100V2-021VHTB2,