ISO 9001:2000 Certificated Cé pay aM @ DNB D25IIs gilenc? OPERATION AND MAINTENANCE MANUAL DNS Co., Ltd.MODEL : D25IIs SERIAL NUMBER : Office (Hankook tire Bldg, 4F) 424 chulean-dong, Gwangmyeong-si, Gyeonggi-do, Korea(423-030) Tel: +82-2-2617-5001 Fax | +82-2-2611-8004 Factory 27-5. Sengjeong-dong. Heungdeok-gu. Cheongit-si Chungcheonabuk-do. Koreal36'-250) Tel: +82-42-267-2500 Fax © +82-19-267-5001 “Spectications and design presented in this manual are subject to change without notice -1-Introduction The DNS high-performance breaker has been developed by concentrating the latest technology based on DNS‘s abundant experiences. Since this equipment has passed strict inspections and tests before delivery, it can be used with ease. This manual describes the construction, correct operation, inspection and repair in order to use this equipment safely and efficiently. Refer to the specified instruction manuals for the Breaker. Before using this equipment, be sure to read this manual and to fully understand the operation, inspection and repair. If you do not follow this manual, any serious accident may occur. LI i —— I} «This equipment should not be used for other works excent the snecified works. «fF this equigment is used carelessly, such an accident as injures sericusly or kills a person may be caused, » The operator end maintenance man should read and fully understand this manual before operating or repairng this equipment, * This manual should be kept near this equioment, and those who use or manage the equpment shoud read it periodically. «If this manual is lost or damaged, order a new one from DNS or DNS's selling agent. «If this equipment is transferred, be sure to attach this manual to the equipment * Since the product has been improved constantly, this manual may not cover alll of the equpment. Please contact DNS or DNS's selling agent for obscure things. * For safety, common items are described in the succeeding nages. * Use this equipment according to the regulations of @ nation where it is used « Illegal waste cisposal has much to do with the environmert destruction cbserve the laws and rules about the waste disposal strictlySAFETY INFORMATION Most of the eccidents are caused by disregarding the basic rules of operation, inspection or repair, or by negectng the inspection before operation. Many accidents can often be avoided by recognizing potentially hazardous situations before snd accident occurs. Before operating, inspecting or repairing this eouipment, be sure to read and fully understand the preventive methods and wamings described on the equipment or in this manual. If not, never operate, inspect or repair this eouipment. Safety lebels and messages are clessifed as follows (based on ISO7000) so that the users can understand the warnings on the equipment or in this manual Indicates an imminently hazardous situation which, if not avoided, will A DANGER resut in desth or serious injury. This signal word is to be limitext to the most exreme sivations, @ WARNING Indicates a potentialy hazardous situation which, if not avoided, could result in dleath er serious injury. Indicates a potentially hazardous stuation which, if not avoided, may A CAUTION resut in minor or moderate injury. It may also be used to alert against unsafe practices. Bi NOTICE — Signs usect to indate a statement of company policy alrsctly or indirectly related to the safety of personnel or protection of property. The safety messages include the preventive measures to avoid danger. ONS cannot anticpate every possible circumstance that might involve a potential hazard on operation, inspection or repair. Therefore the wernings in this manual aro not all inclusive. If an operation, inspection or repair not described in this manual is used, you must take measures for safety by yourself.1. SPECIFICATION 1.1 General specifications of DNB D25ils .. 2. GENERAL INFORMATION 2.1 Position of Identification Detail and Sign plate .. 2.2 Safety ... 2.3 DNB D25ils 24 Principles of operation 3. OPERATION 3.1 Correct working methods .. 3.2 Operating temperature .... 3.3 Aduster 3.4 Replacement timing of tool bushing, tool 3.5 Charging Nz gas .. 4, MAINTENANCE 4.1 Service instructions for operator. BRB 4.2 Inspection 4.3 Yearly service 4.4 Hydraulic oil 4.5 Lubrication 46 Long term storage 47 Cleaning the hammer... 4.8 Trouble shooting ... 5. DISASSEMBLING AND ASSEMBLING THE DNB D25lls 5.1 Removal and installation of toole..... £8 5.2 Removal and installation of the hammer 5.3 Discharge and charge Nz gas of back head &5.4 Loosening and tightening through bolt 5.5 Disassembly and assembly of the back head ... 5.6 Dissembly and assembling of piston seal housin; 5.7 Disassembly and assembling of tool bushing .. 5.8 Disassembly and assembling of control valve ass’y 5.9 Disassembling and assembling the seal housing 5.11 Disassembling and assembling the cylinder seal .. 5.11 Assembing screw set .. 5.12 Disassembling and assembling silencing part 6. INSTALLATION 6.1. Instaling the hammer. 6.2 Hydraulic installation. 42 6.3 Measuring hammer operation prossure... 7. PARTS UST 7.1 DNB Dells Tools .. 7.2 DNB D25ils Breaker .. 8. SERVICE DATA 8.1 Main inspection. 8.2 Yearly service .. 8.3 Tightening torques... 8.4 Application of sprays and greases.forsFlel( yam DT SPIEGIFICA THONS 1.1 GENERAL SPECIFICATIONS OF DNB D25IIs @3) 2 | 4174 863, 6 = 205 205 UNIT ; mm Working weight 200 ka Back pressure 5 bar Impact enerdy 360 Tool shank diameter 260 mm Number of strike 58 ~ 1100 bpm Operating pressure 120 ~ 140 bar Oil temperature -20~ +80 Pressure seliet (min) 160 bar Hydraulic oll visecsity 15~1,000 oSt Oil flow 25 ~ 50 Ipm Carrier weight 18-5 bn Line size Back head pressure 19 bar Pressure ine 12 mm Return tne 12 mmChapter General Iniormaiion 2.1 Position of Identification Details and Sign plates All safety instructions and hazard wamings on te equipment must be kept complete and in a perfecty legible condition. It is your responsibilty as owner and operator of the equipment to ensure that any safety instructions or warning plates on the machine that have been damaged or rendered illegible are replaced without delay. {OUT v Do wear ear protection or keep over 7.5m distarce away as over 85dB can make heanng disorder. Do keep over 20m away from work site as flying debris can make person dangerous. As spraying pressure of Ne gas van make eye sight lose, do a work after discharge of Ne gas. >| | In air frighting, Ne gas must be discharged as there is possibilty to explode. IDNB D25ils DNS Co., Ltd. + This manual is a guide to the safe operation and maintenance of your ONB C25IIs HAMMER, + Read this manual carefully before installing, ‘operating or maintaining this equipment. + The hammer is a powerful tool. Using without proper care can causa damage. + Be sure to use it comectly Chapter 3 Operation is to assist you in the safe use of the hammer. Special attention should be paid to all safsty notices. They are to warn you of possible hazards. eR Aub it ‘Always be aware of potertial hazards. *To avoid inlury or damage always & CAUTION séhways adhere strictly to safe working practices. ‘Failure to do so could result in injury to the operator or cthers and possible damage to the equipment * You should be a competent operator of the carrier machine ty use hammer correctly Do not use or install the hammer until you ean use the earriar machine. To not tush the job of learning. Take your tima and learn safely. * if there is anything you ¢o not understand, ask your DHI Service Center for advice, + Hammer Model and Serial Number + This manual prepared for dealing with the ONB D2sllc. + D25IIs is designed tor breaking oversized boulders, + and demolishing reiniorced structures, Serial numberDNB D25iIls DNS Co., Lid. +The weight of the O25Ils is 200ka together with tools. hoses and adaptors. +The impact energy of te hammer is constant and independent of the carrier's hydraulic system, +The DESIIs is designed for maior heavy exeavation and clearing work “The hammer serial number is stamped on a metal plate, whieh is in the cyihder, near the out-Ine connection + Comeet raferanca to the sorial numbar of tha hammer is important in case of repairing oF ‘ordering spare parts. Maintaining and identfying parts for spectic hammer is possible only through serial number. + Using the Manual +The purpose of this manual is to give you an understandng of the equipment and its safe ‘operation. It also contains maintenance informaton and technical spectications. + Study the manual thoroughly before using or maintaining the hammer. if you do not understand anything or you are unsure, consut your DH Service Centar. Do not guess. Read all tha safety statements carefully, Always work carefully and safely & NOTICE * CARE AND ALERTNESS * Every time you work with the hammer, handle with care and stay alert. Always be careful. Always be alert for hazards. 2.2 SAFETY +f oparated witheut cara or correct maintenance, all mecharieal equipment ean be hazardous. + Read and understand the warning messages of this manual. Thay tell you of hazards and how to avoid them. If you do not understand he messages, consult your amployer, your D2sIls daalar or DMI Sarvioe Canter. + Safely is not just a mattar of responding to ‘he warnings, + Whenever you ae working with your O25IIs hammer you must consider what might be possible hazards and how to avoid them. * Do not work with the hammer i you are unsure of iis operation. + Do not start any operations unlass you and ‘hose around you are safe +f you are unsure of anything about the D25IIs hammer or the job, consult a ‘echnician + Do not assume anything You must cheek it ‘noroughy. CFL ity First read careiully the following waming messages. They will keen you from hazards and how to avoid them. lf proper precautions are not observed, there is a risk of injury.DNB D25iIls DNS Co., Lid. 1) Manuals a. Read this manual before installing, operating ‘or maintaining the hammer. if thare is anything undear, ask your employer or your DHI Service Certer tor detais. b. Keep this manual in good condtion 2. Olothing a. Vou can ba injured it you do not wear proper ckthing. Loose clothing can get caught in the machinery. Wear protective clothing to sut the job. Examples are: a safely helmet, safely shoes, safely glasses, ‘wall-fting overalls, ear-protectors and industial gloves. Keep cuffs fastened. b. Do not wear a neckte or scart and keep long hair restrained. + Lifting Equipment +The use of faulty Ifting equipment can cause an injury, + Make sure that the lting equipment Is im good condition, + Make sure that lifting tackle complies with all local regulations and is sutable for the job. + Make sure that lifting equipment is strong enough for the Job and you krow now to use it & CAUTION! * Read carefully following safety messages. Failure to follow these safety practices could result in inury to the operator or others and possible damage to the equipment. ¥ Regulations and Laws # + Obsene all laws, worksite and local regulations which affect you and your equipment. # Pracitice® + You and cihers can be seriously injured ft you carry out unfamiliar operations without practiong them firt + Practice away trom jobrsite, on a clear area, + Keep other people away. + Do not perform new operations until you ara sure you can operate them safely. ¥ Equipment Condition # * Detective equipment can injure you or others. Do not oparate equipment which is defective ‘or has missing parts. + Make sure the mantenanee procedures in this manual are completed before using the equipment. ¥ Equipment Limits # + Operating the equipment beyond its design limits can cause damage. It can also be dangerous. = 10 -DNB D25iIls DNS Go., Lid. + Do not oparate the ecuipment beyond its limits + Do not tty to upgrade the equipment’s performance with unapproved modifications 3) Communications: a. Poor communications ean cause aceidants, b. Keep people arcund you informed of what you will be doing. c.f you will be working with other people make sure ‘hey understand any hand signals you will be using d. Remember work sites ate noisy. Please do ngt rely on spoken commands. 4) Work site a. Work sitas can be hazardous, b. inspect the site before workhg on it ©. Check for potholes, weak ground, hidden rocks ete. . Cheek for utes (electre cables, gas and water pipes etc.) 2. Mark the positions of underground eables ard pipes if you will be breaking the around near tp tham. ¥ Safy information Protector 5) Metal Splinters, a. You can be injured by t¥ing splinters when driving metal pins in and out b. Always wear safety passes, 6) Banks and Trenches a. Banlad material and tranehas can collapea b. Do not work too close to banks and trenches where there is a danger of collapse 7) Safety Barriers a. Unprotected aqubment in public places ean be dangerous, b. In public places, or when your visibilty is reduced, place bartiets argund the machine fo keep people away. -u-DNB D25iIls DNS Go., Lid. ACAUTION! Obey all safsty regulations and aways be alert to hazards. ACAUTION! Grease the hanmer regularly during operation Do not operate the hammer as a standard assembly under water, oF fi will be damaged Pay careful attention when lifting and haneling, 8) Repairs and Maintenance 2. Do not tty to do repairs or any other maintenance work you do not understand b. Unapproved repairs and/or maintenance can cause Injury and damage. Dentact your DHI Service Center for adviea before repairing and/or maintaining the hammer. 9) Hydraulic Pressure & Hydraulic tluid at system pressure is, dangerous. b. Before disconnecting or connecting hydraulic hoses, stop the carrier engine and operate the controls to teleese pressure trapped in the hoses. © Keep people away from the hydraulic hosas during hammer operation. = 12 -DNB D25iIls DNS Go., Lid. 23 DNB D25IIs #Main Components# 1) HAMMER 2) HOUSING 3) UPPER BUFFER 4) LOWER BUFFER 5) TOP COVER te ra = 13 -DNB D25iIls DNS Co., Ltd. 2.4 PRINCIPLES OF OPERATION ‘The relaton between the pressure afected area Ay of the Piston rear chamber and tha pressure affected atea Az of the piston front chamber is Ay > Az . High-pressure ofl is always applied to Az and, when oil pressure applied to Ay Is changed fom high to low pressure and vice versa, Piston Cz reciprocates, Similarly the relaton between the pressure affected area Ag o1 the vaWe high-pressure chamber and the pressure alfected area A, > Ay High-pressure cil is always applied to Ag and, when the oil pressure applied to Ay & changed from high to low pressure and vice versa, valve Ca changes io ater the port to the piston rear chamber By from the high-pressure side > the low-pressure side and vice versa and, in accordance with the reciprocation of valve C4 , pbton G2 teciprocates Further the back head is charged with Ne gas When the piston moves backward, the Ne gas is compressed 1o slore the gas energy and, when the piston hammars, the gas energy is converted into piston hammering energy. Piston start up> When hich-pressure of is applied to the IN port of the hydraulic breaker, the high-pressure oil acts upon the Piston front chamber Az and vaNe high-pressure chamber Vi fo hod down the vale. As the piston rear chamber B, is connected to the OUT port through the vave, The piston Ce stars moving backward under the high-pressure cil applied to the pressure affected area Az of the piston ‘ont chamber. a 4 is a a 4 = ta -DNB D25iIls DNS Co., Ltd. valve charging™ vihan the piston movas backward, The high-pressure of c's upon the valve change V+ and the valve changes. At this time, the piston rear chamber By is dsconnected ¥" our 7 ‘7 from the valve low-pressure chamber Vs and connected to <= ph Bt the vaWe high-pressure chamber Bs and pressure in the x5 piston rear chamber 8 nereases. NW —_I ~ oe b = 4 when the piston G2 teaches top high-pressure cil from te valve high-pressure chamber Bsacts upon the piston rear chamber 8; At tha same time the piston moves forward and impact the tool ‘The vave is held open because high-pressure chamber vs BI = 15 -for el(aae S OPERATION + This chapter descrizes the correct working methods and how to choose the correct tool for the job, + To inoraase the hammar's working iile, pay articular attention to correct working methods. +The hammer is a powerful machine and lols of damage can ba done i you do not krow how to use it correctly + Read this chapter betore operating INE hammers, Choosing Tools DHI can offer a selection of and special tools to suit each application. The type of tool must be selected 19 get the best possible working results and life time for tool 1) Blunt + For igneousle.c.granite) and tough metamorphic roek(e.g.gneiss) into which tool doesn't penetrate * Concrete * Breaking boulders 2) Chisel and Moll + For sedimentary (eg.sandsione| and weak metamorphic rock into which tool penetrates * Concrete + Tranching and benching Principles of Breaking + There are basically two ways of breakng with a hydraulic hammer. a) Penettative(or Cutting) Breaking ‘In this form of breaking the moil point or chisel tool is foread insida tha material. This method is mest effective in soft, layered or plastic, low abiashe material = | 5 EEX => b) Impact Breaking In impact breaking, material is broken by transferring very strong mechanical stress trom the tool inio material tp be broken. Bast possible energy transiar between tool and ‘object is achieved with a blunt tool Impact breaking is most effective in hard, brit and very abrasive materials The bbw energy of D2SIls is suitable for the impact breaking operation oo 69 TTT TTT IONB. IDNB. i il Ss = = = te -DNB D25iIls DNS Co., Ltd. 3.1 CORRECT WORKING METHODS, 1) Prepare the carrier for normal excavation work a. Move the cartier to a required positon . Engage the parking brake ©. Sat the crive to neutral 4. Disengage th boom lock lif fitted). 2) Set the engine spsed to the tecommended engine RPM, 2) Place the tool against the object at $0 agrees. 1. Avoid small imegularties on the object which can break easiy and cause either idle strokes of incorrect workiig angle b. Incorrect working methods may cause failure in the operation of hammer or housing 4) Use the excavator boom to press the hammer fimly against the object a. Do rot pry the hammer with the boom, b. Do not press too much or too iitle with the boom --DNB D25iIls DNS Co., Lid. 9) Start ne hammer. 4. Do rot allow the hammer to fall down and rake idle strokes whan te object breaks 6) Do net let the tool move outwards from The constant idle strokes have a hammer when t penetrates, deteriorating effect on the hammer. + Feed the hammer all the time with the b. It hammer falls cown, side-plates wear out exeavator boom. rote quickly. 7) Keep the tool at 80 dagrees at all times. 9. Do net stike in one spot for mora than 15 seconds ai a time a. It object moves or its surface breaks, correct tha angle immaciatoly. “If an objact doas not break, styp tha b. Keep feed force and too! aligned. hammer and change the position of the tool which dampens the impact effect and cause ©) Sp he hammer quickly the tool to overheat Oo x oe TP Wax 15 sec HEATING COMPOUND ‘STOP Now Normal Option = 1g -DNB D25iIls DNS Co., Ltd. 10) When breaking concrete, hald oF frozen ground, never strike and bend wih the tool at the same time a. This action may cause the tool to break b. Bending may be caused by stone which is inside hard or frozen ground ¢. Stop string if you tnd sudden resistance under the tool & NOTICE Listen to the hammer’s sound while you are using it «If the sound becomes thinner and the impact less efficient, the tool is misaligned with the material andlor there is net enough “pressing” force on the tocl * realign the tool and press the tool firmly’ against the material & CAUTION! The hammer 2s a standard assembly, must not be used under water. * If water fills the space where the piston stikes the tool, a strong pressure wave is| generated ard the hammer may be damaged, 3.2 OPERATING TEMPERATUE “The operatng temperature is -200~80U (Fr ~176 °F) if the temperature is lower then -20%(-4*F), the hammer and tool must be preheated betore starting the operation in order to avoid breakage of the accumulator membrane and the tool. During the operation they will remain ‘warn, -20C = 19 -DNB D25iIls DNS Co., Lid. 3.3 ADJUSTMENT OF NUMBER OF BLOWS AND IMPACT FORCE. 2. Check the hydraulic hoses. Replace t neoassary. Do not lot dirt gat into the hammer or hoses. 4.2 INSPECTION 1) Check all hydraulic connections 2) Check that the hydraulic hoses do not rub against anything in any boom position. 3) Replace the hydraulic oil fiters of the carrier. 4.3 YEARLY SERVICE 1] After 600 operating hours, yearly service is recommended i be catried out by your DHI Serviee Center. 2) Contact your DHI Senice Center for more information about year servica 4. Check all hy¢raulc connections, D. Check that the hydraulic hoses do not rub against arything in any boom postion. ©. Replace the hydraulic oil fiters of the carrier. = 22 -DNB D25iIls DNS Co., Ltd. AA HYDRAULIC OIL, a. Generally the hydraulic oll originally intended for the carrier to be used in the ONE hydraulic hammer. D. However working with the nydraulle hammer will heat the oll much more than normal excavation work, the viscosity of the oil must be checked. ©. When the hammer is used continuously, the temperature of the hydraulic oil normalizes at 4 cerlain level depending on gondilions and ‘on tha carrier At this temperature, tha viscosity of the hydraulic oil should be 20~ AeSt (2.50~ 5.35°E). d. The ONE hydraulic hammer must not be started if the visoosity of the hydraulic ol is above 10000St(131°E) or operated when the viscosity of the hydraulic oil is below 15e812.35°E) 1) When the oil is too thick, the following problems may occur: a. Difficult start up. b. Stiff operation cc. Hammer strikes irregularly and showy 4. Danger of cavitation in the pumps and hydraulic hammer e. Sticky valves 1. Fiter bypass, impurities in oil not removed 2) When the oil is thin, the following problems may occur Efficiency losses (intemal leaks) b. Damages to gaskets and seals leaks ©. Accelerated wearing of parts, because of decreased lubrication efficency & NOTICE DHI strongly recommends dfferent hydraulic ots for use in summer and winter if there is an average temperature difference of more than 35°C(85°F). The correct hydraulic oll viscosity would thus be ensured. 3) Special Oils + In some cases special oilsie.g.biological oils and non-infammable ois) can be used with DNB hydraule hammers. Otserve following aspects when considering the use of special oils: a. The viscosity range fh the special oil must ba in tha given range of 15~1,000 e8t(2.35~131°E) B. The lubriation properties must be adequate A NOTICE * Although special oil could be used in camer, always check suitability with hammer due to the high piston speed in| hammer. ¢. The corrosion resistance properties must be adequate, d. Contact the oll manufacturar or DH Sarvica Center for more information about spacial oils. 4 cleanness of hydraulic oll +A seperate fitter iS not required when the ONE hammer ‘installed in the hydraulic etreut. +The hydraulic oil fitar of the carrier will clean the oil flowing through the hammer. +The purpose of the oil fer is to remove Impurites from the hycraule oll since they cause accelerated component wear, blockages and even seizure. = 23 -DNB D25iIls DNS Co., Ltd. ‘impurities also cause the oil to overheat and deteriorate. Ar and waler ate also Imputiles in oll ‘+ Not all impurities can be sean with the naked eye. a. Impurities enter the Hydraule Syster + During hydraulic of! changes and refiling + When components are repaired or serviced, + When the nammer is being installed on the * Because of component wear 9) 1 fiter “When working with hycraule hammers, the carrier oil fiter must fulfil the folowing specifications: a. The oil fiter must be rated at 25 microns maxirum b. The oil filer must be a high quality pressure fiter rated to maximum working pressure ©. The ol fiter must have a volume flow capacty of at least twice the nammer's maximum flovt 4. The cooler must withstand 2 dynamic pressure of 230 psi (20bar) @. Il the carers oil cooler is too small either the orginal cooler must te replaced with a larger on or an auxllary cooler must be installa °c Viscosity [Point Name of Olt [25-30 9 10 20 90 49 50 60 70 & st cy sear ao |e he rz 468 =35, este Hyareutt zos | 4 & 223 “8 i ee | x3 Bove Univ nse sie | 45 N46 P 45.7 39 Texaco Rando Cil va | os met 28 | <8 reto Hydrautie of zo | ‘| GRR Al 8 | 8 oot prea aq | W35 i : 3 Hie Hy gi | 28 Motor oils tov by | 40.0 BYe0 | oo | xe a3 we | 2g a7, Bo 2 ee 8 154/30 100 OLLIE. 100 ERI Permitted oil temprvature Recommended oil temprvature. = 24 -DNB D25iIls DNS Co., Ltd. 6) The auxilary hydraulic cooler can be installed a. In front of the radiator, in which case an additional fan is rot required, ie, maximum rise cf the ecoling air is 80 40°F) ®. Any other sutabl place, using 2 tan either hydraulically or electrically driven ©. If the oll tamperature is fill foo high in spite of the coolers, please contact your DHI Service Center 7) Damage caused ty hydraulic oll contamination in the camier and hammer circuits a. The working life of the pumps is significantly shortened + Premature wear of parts + Cavitation b. Valves do not function property, * Spools bind + Premature wear of parts * Blocking of small hoes © Wear of cylinders and gaskets. 4. Reduced hammer efficiency. + Premature wear of moving parts and seals, + Danger of piston seizng up + Oil leakage ©. Shortened working life and reduced eificiency of hydraulic off + Dil overheats + Oil quality deteriorates + Ekctro-chemical changes in hydraulic of = 25 -DNB D25iIls DNS Co., Ltd. 4.5 LUBRICATION Prats 1) Frequency « IMPORTANT Do not fill the space between piston and 4 Every 2 Hours for continuous tool with grease. operation or Daily # 2) Insuffeient greasing may cause: lubroated day. t ite hours) a. Abnormal wear of tool bushing and tool lubricated daily. (once in a shift’ hours) >. Tool breakage b. Adapt interval and amount of grease according 19 wear rate of tools and workng a. The grease fitings for wear plates must be 4) Grease Specttication codons © Tool shank must be well Wbicated belore a. No cropping point in the condition of over instaling the tool 2500 (éa0°F) b. Should be worked over themax 150% (00°F) . should be worked under the lowest air temperature. d. Appendix MoSe, Blank lead or equal stuff ®. Density: NLGIO~2 glade 1. Should be water resistant op = 2 -DNB D25iIls DNS Co., Ltd. 5) Recommended Lubricants: ESSD EDL 232 WYNNS GS80 SHELL Kuggiet SHELL Extrema MDS KL BER Unimoly GB2 Le 8751/5752 span ge - 27 -DNB D25iIls DNS Co., Ltd. 4.6 LONG TERM STORAGE + Dbay following points when the hammer is. storad 1) The Storage area must be dry. 2) The lower end of the piston, iool and bushing Trust be well protected wih grease 9) Connections must be sealad with olaan plugs to prevent oil leakage and ditt from getting into coupings 4) The hammer must be stored in the vertical postion 5) In casa of keeping for a long time (more them two week) ® Remove the tool of the main body of hammer ® Release completely charged Nz gas from the back head © Pula bar on the piston impact part in he direction of the from head and push the piston up striking slightly by small hammer. @ Apoly grease to the insde of the front head. €) Make sure the hammer would not fall 7) In this way the vital parts of the hammer are protected from rust and the machine is ready to be used whenever necessary. 4.7 CLEANING THE HAMMER 1) Before cleaning the hammer, plug the pressura and ratum line. Otherwise, Dirte can enter into the hammer ang this may cause damage to the hammer. 2) Olean the outside of the hammer with a steam cleaner. 0 = 28 -4.8 TROUBLE SHOOTING GUIDE @ This ‘rouble shooting guide has been prepared to aid the operator to locate the probable cause and then remedy when t following chect1) impact forea is weak3) Hammer does not strike 4) Gas leakageDNB D25iIls DNS Co., Ltd. Notiea : Contact ONE sarviee shop when the operator practica disassembly and assembly. Especially, when practicing technical disassembly and assembly. Notice : 1. Every contact surface should be assembled after application fo hydraulic oil Same tools should be used in disassembly or reassembly When handing o-ring and packing. They whould be done by naked hand.isze pictures) O-thg and packing assembled must be greased Usage of Thread tate Wind Thread tape on the object serveral lines. Please do it tightly (Pay altention not ty become wet) = 32 -Chapter Ey Disassembling and Assembling Tihe DNB D25Te Pec) Do not attempt to disassemble or => mon © ®@ O@ assemble this equipment before reading through this chapter of the manual fist. Dru POOOD © A 5.1 REMOVAL AND = INSTALLATION OF TOOLS < 1) Ramoval Aa a. Place the hammer on level ground. & D. Make sure that the art's transmision is In neu ang the paking brakes engaced ©. Stop the engine ® 2 4. Remove rubter pug A, using sctewsrve, $ ®. Remove the lockng pin 1 Remove rubber pig © using screws . Remove. tool pin © 3 h. Remove the tool E, te +O a, 2) Instatation ¢ 4. Glean and lubricate te tool and the tool ® oh > b. Install the tool E, tool pin D, and locking c o th 8 Chock that the tel ln © Io eecured by the looking pin 8 c 4. Install the rubber plug © @ @. nsal ihe rubber Blup A e ° Mi} “o > = 33 -DNB D25iIls DNS Co., Ltd. 5.2 REMOVAL AND INSTALLATION OF THE HAMMER 1) Removal cf REMOVAL a. Remove the tool and set the hammer STALL to the vertical posttion on the floor and support. Make sure that the hammer ean not fall whan the exeavator is taken aside b. Disconnect the hoses and plug them as well as the hammer inlet and outlet. ©. Open the top cover bolts AIM16,10pcs) d. Remove the top cover & carefully e, Remove upper butters 0. 1 Lit me hammer out of be housing and replace the wearing plates. 2) Installation After changing the wearing plates set the hammer into the housing, and check tne clearance by shaking the hammer b. After placing the hammer into the housing, Upper butter and mounting braokattiog cover) ara put in thair places: ©. Tighten the top cover bots A(1Opes). 4. Install the tool A I] a U o | e 0o = 34 -DNB D25iIls DNS Co., Ltd. 2) Changing the Wearing Plates. a. The distance between the wearing plates A: 130mm) B+ 1gomm YA = 35 -DNB D25iIls DNS Co., Ltd. §.8 DISCHARGE AND CHARGE Nz GAS OF BACK HEAD 1) diseharge of Nz gas in the back head. Na pas instie Back head shoukl be completely removed. if not 50, explosion may cccur, when through bolt is loosened. Notice the procedure lowing the gas pressure Do not attempt to disassemble or assemble this equipment 2) Charge of Nz gas in the back head Install charghg adapter on charging valve of back head 1 connection of Na gas botle charge back head with Na pas (1ba) Inset charging valve cap of back head. Used tools Spanner 17 x 19mm Na bottle Charging device set = 36 -DNB D25iIls DNS Co., Ltd. 5.4 LOOSENING AND TIGHTENING THROUGH BOLT 1) Loosening Through bot & Nut can be disconnected in use of power wrench of, hammer wrench can be used. Not bosening it completely, but do only until t ean be tumad with hand 2) Tigntening Clean the through bolt and the contact surace of the through bolt Grease the screw threads of through bot. Tighton it st a half dograe a regular torque toward the diagonal dirzction Tighten it at a regular torque. {360 Nm) Use tools Torque wrench 350 Nm Socket wrench 2 mm 5.5 DISASSEMBLY AND ASSEMBLY OF THE BACK HEAD 1) Disassembly = Separate back head in use of host ¢r chain block. - © Used wos Hoist = over 05 Ton Lifting eyes - MI2-x PLI5 > Take out O-ring. - © 2) Assemble ~ Put O-ring to back head ft O-ring to the top of cylinder and apply grasse to t- © ~ Insert joint ring into the top of back head connest in with cylinder, using hoist or chain block - @ = 37 -DNB D25iIls DNS Co., Ltd. 5.6 DISASSEMBLY AND ASSEMBLING OF PISTON, SEAL HOUSING Fit the M12 Ifting eyes on Piston - © Lift piston upward ftom Gyinder carefully, and it could be lakt according to job ste situation, Stand Piston removed, and separate Seal housing from Fiston topping the lower part of Seal housing in use of rubber hammer. Screw MI2 Liftng bolts on Cylinder, and lift carefully upwards to ba laid, using hoist ‘or chain block, 2) Assembling of piston and seal housing Lift Cylinder to fit into Front head. Put it into ylinder slowly, lifting with Hoist or Chain block. - © ‘When Seal housing is inserted, Plastic or Rubber hammer should ba usad. And strike it, putting on rubber plate. Used 0015: Fubberhammar 2 be 5.7 DISASSEMBLY AND ASSEMBLING OF TOOL BUSHING 1) Disassembly a)Rempve the locking pin A. B)Remove the tggl bushing B from the front head, using sleeve puller ‘)t tool bushing is tight, warm the under part ‘of the front nead. D)Chack tool and tool bushing for waar 2) Assembling a)Clean all parts, b)Apply MoS2 spay to the conlaci sullace of Tool busting and Front head }instal Tool bushing B instal locking pin A = 38 -DNB D25iIls DNS Co., Ltd. 5.8 DISASSEMBLY AND ASSEMBLING OF CONTROL VALVE ASS’ Y 1) Disassembly Insert the MB bolts into the upper part of Control valve plug and pull out Control valve toward th arrow 2) Assembly Install O-ring t9 control valve plug, brush hycraule of Cheek tha movement condtion after inserting Control vate 5.9 DISASSEMBLING AND ASSEMBLING THE SEAL HOUSING 1) Disassembly When Packing, all kind of O-ring ara disassembled, be careful nol to damage them ffiming = When oil flows into Back head When Nz gas inside Back head leaks out toward Cylinder When striking is in_tregulat condition 2) Assembly of Seal housing Assembly of Packing Assemble it, by paying attention to the direction on Packing to be set CAS SEAL, \ STEP SraDNB D25iIls DNS Co., Ltd. 5.10 DISASSEMBLING AND ASSEMBLING THE CYLINDER SEAL 1) Disassembly Remove Seal from Oylinder carefully, using ‘ool for disconnecting Seal i U-PACKING GES | DUST SEA. [Timing = When ol is heavily lealing down Chisel 2) Assembly Brush hydraulic oll over the part that Seal is set and fit Packng, Fit Packings and check thay are in good itness. And then, apply grease over the part 5.11 ASSEMBLING SCREW SET 1) Insert screw set with L wrench, wind tape. After turing. Tyhten i strongly. ‘At this time, soraw set should be kcated at Jower level than the upper part of Cylinder. Used wols Lwrench mm, émm_8mm = 40 -DNB D25iIls DNS Co., Ltd. 5.12 DISASSEMBLING AND. ASSEMBLING SILENCING PARTS. 1) Disassembiing 2, Remove the plug A,B,D,E from housing, , Disascemible tho IN-OUT heses from The Hammer ¢, Remove the cover C 4d, Remove the tool, 2) Assembling 2, Intall cover C b, assemble the IN-OUT hoses from ‘The Hammer, ¢, Install the plug ABD into housing - al -Chapter fT INSTALLATION & CAUTION! 2 Line Size 4. Oil flow: 2550 Imi Incorrect installation can cause premature * pressure tine: 12mm, failure and possible damage to the return tine: 12mm hammer and to the carner. Do not install >. Too smal line ste causes: DNB D2ais hammers if you are unsure ”° Contact your DNB distributor, DH Servioe + nereased back pressure Center or your Iccal carier dealer for more + increased operating pressure information + imeguiar blows * overheating oll 6.1 INSTALLING THE HAMMER & Mine Is 0 28 + more expensive components 4 It is possible to install the ONB O25IIs on any carrier whieh meets the necessary hydraule: ¥Ouring installation of the D25IIs, the tollywing and machanical installation requirements. hoses and pipes are recommended to ensure that the oil tlows correctly and the pressures > Observe the following general points when fare withn tho oorract limite instaling the hammer: a. Ensure that the ONB D285l[s is positioned on 3) Hoses [for Standard Fiting) firm, level ground before instaling or remouing it b. Il tha hammer has to ba in the vertical position for installng or removing, ensure that a. Prassura hosa SAE 100 R2~ A(t b. Return hose SAE 100 R2~ 11/2 it is supported safely 4) Pressure and Aelun Pipes ©. Postion the carrier safely, e.g. parking brake engaged, engine stopoed, hycraulle pressure a. Cheek max. workng pressure released trom D25Ils supaly noses . Seamiess precision steel pipes ©. Sie according to recommenced ine size 1) Hoses and Pipes 6.2 HYDRAULIC INSTALLATION When selacting Ine components check #4 suitable oll supply is the most important factor + correct line size = for correct operation of hycraulle hammar. + max. working pressure * suitability for high vibrations + suitability 19 hammer's hese connector 1] Increase the Flow Causes an Increase in the Operating PreassureDNB D25iIls DNS Co., Ltd. 2) Flow Control valve a. The hammer needs a flew control valve it the output of the pump is more than the maximum allowed for the harime b. The oil fw controls the impact rate of he hammer. 9) Prossura Rolict Valve a. The pressure relief vaWve is a salety device which is used to protect the hammer when the pressure rises in the hydraulic circu b. The operating pressure of the hammer determines the setting of the pressure roliaf valva in the pracsura tina ©. The pressure relist valve sating should be approx. 290 psil20 bar) higher than hammer's ‘operaiing pressure 6.3 MEASURING THE HAMMER OPERATING PRESSURE 1) Operating Pressure a. Hall the earrer engine b. Assemble the hich pressure gauge 2625 psi (250bar) to the high pressure measuring portlR 1/4"). Start the engine. Sat the tool of tha hammar a.g. on a thick steel plate Adjust operating enghe revolutions and start to operate the hammer. Read the averan pressure fom the high Pressure gauge = operating pressure. Operating pressure is preadjusted at the feotory and thare should be no reason to adjust it Stop the carer and remove the gauges. Tighten the plug of the pressure measuring point, torque 33Nm 33kpm. 24 Ibf tt). = 43 -7A Chapter W% PARTS LIST TOOLS STANDARD TOOLS A B NAME Chisel too! Moi point LENGTH 582 mm 592 mm WEIGHT 85 ke 85 ko DIAMETER 260 mm 260 mm. NOTE ~ 44 -DNS Co., Ltd. DNB D25iIls {CODE + 23502534) 7.2 DNB D25Ils BREAKER 38 HANMER PART = 45 -DNS Co., Ltd. DNB D25iIls DN B D25is - 4 -DNB D25lls DNS Co., Ltd. MODEL NAME : ONE D25ns NO. PART NO PART NAME DESCRIPTION = QTY REMARK 1 S&-g10 BACK HEAD Teac anKTeO 7 2 9511-0530 CHARGING VALVE PR 1/2 1 3 9511-0540 CHARGING VALVE CAP MIOxPI 5 1 4 92-0120 GYUNDER 217.5x 120% 60 1 5 gee2-0190 PISTON DeaaceL 1 6 982-0140 SEAL HOUSING Deseo. 1 7 982-0150 FRONT HEAD ax aae8 1 8 982-0180 TOOL BUSHING DesHGOL 1 2 gee2-0190 SIDE BOLT MeDxP2-5coL. 4 10 (06-108%6 «GREASE NIPPLE Prtlt 1 11 982-0440 SIDE BOLT WASHER DazAL 4 12 92-000 SIDE BOLT NUT(H) Monxr2 4 13 geez-wag VALVE SLEEVE aaa 1 14 gs02-ceg0 VALVE DeneaL 1 15 982-050 -VALVE PLUG 03826. 1 16 © 982-0860 TOOL FIN camesL 1 17 Az-AGOOGa =~ SPRING PIN DML 120 2 18 9511-0490 ACUUSTER NUT HExae-Les 1 19 982-0600 CYLINDER ADJUSTER Mr4xF2.0 1 202700727 NIPPLE PRI PF 2 21 911-0460 GUIDE PIN DI2L25 2 22 1-001285 LOOKING SOREW Pros 1 2 IG-0N1284 LOOKING SOREW Prd 2 24 15-001283- LOOKING SOREW PRI 5 25 © 9f2-1930 CHISEL TOOL DenseaL 1 26 © 9822-1910 MOIL POINT TOOL Demse2t 1 2 FI-IS8715 DUST SEAL DS 597567.7x59 1 28 FEISTI14 —U-PAOKING 1S) 897367 7x69 1 2a Fo-123623 O-RING Ge-18 3 a FOI@IZ? O-RING PIeIB 3 a FOI0I70. O-RING Puce 1 2 Fo-1ce223 O-RING Pe0r1B 1 S% FO-108828 O-RING PSI-IE 1 34 F3-AO0IZ0.—«STP SEAL SBEXTOES 2 25 FO-AQDIGN. «GAS SEAL 585x65,7.1 1 2% 94-210 HOUSING 1 SF 94-2110 TOP COVER At SC7EKI A 1 984-4120 UPFER BUFFER 13031 20368 1 so 9824-9100 LOWER BUFFER 150x1503253 1 4 BI-I7IT73—-HEXA BOLT MI6xP2.0-851. 10 41 o5-111819 WASHER #16 10 42 CI-111864 HEXA NUTE MI5xP2.0 10 — 47 -DNB D25Ils DNS Co., Ltd. MODEL NAME : DNB D25is NO. PART NO. PART NAME DESCRIPTION QTY REMARK a 541-2210 Be COVER Tess 2 44 9534-2000 Be COVER SaTaS 1 45 9824-3190 COVER SEAL Tosseeat 1 48 9594-2020 PLUG De2K1SL. 3 47 144-2270 PLUG napeol, 2 48 00-00I617 EYE BOLT BEIS 1 49 9524-2030 LOOKING SCREW Mig 1 = 48 -Chapter By SQFUGS DAZ 8.1 MAIN INSPECTION 1) During installation inspection or betwaan 60~ 100 ‘operating hours. @. Check the operaiing pressure of the hammer. b. Check the temperature of the hydraulic oi in continuous operation, max. BO'C(176°F) ¢ Check the efficiency of the hammer, impact rate land hammer's avanness in oparation d. Check the pre-tightening torques of all bots and tighten all bots that are othenwise loose. @. Check all hydraulic connections 1. Check that the hydraulic noses do not rus against anything in ary boom posttion 0. Replace the nydraulle oi fiters of the carrier 8.2 YEARLY SERVICE 1) After 600 operating hours a. Change all sealings in the hammer and tha accumulator diaphragm, b. hack all hammer parts and either replace or fepait damaged parts, ©. Measure the oil supply in the hammer circut, pressure imtation and the back pressure . Adjust or repair if necessary. 2. Replace the hydraulic oll titers of ine 1. Check all hydraulic hoses and replace it necessary, 8. Chack the hammer's operation pressure, efficiency, impact rate and evenness of ‘operation as well as the hydraulic oll temperature in contnuous operation = 49 -DNB D25iIls DNS Co., Ltd. 8.3 TIGHTENING TORQUES: tem | Nm | Kom | itt Part Name Oty A so | ss | 412 HEX BOLT 12 B 30 a0 45 NIPPLE 2 c ao | ao | ars THROUGH BOLT 4 E 900 30 675 THROUGH BOLT - NUTIH) 4 F 60 60 6 CHARGING VALVE CAP 1 G 30 a0 @ CHARGING VALVE 1 H ao | 20 180 ADJUSTER NUT 1 = 0 -DNS Co., Ltd. DNB D25iIls DN B D2sIsDNB D25iIls DNS Co., Ltd. 8.4 APPLICATION OF SPRAYS AND GREASES item Remarks A Tool grease(tool and inside tool bushing, tool pin...) c Thread grease, eg ROCOL J 168 and MOLYKOTE BAZ 0 Molybdenum disulpnide spray (Mos2) E O-fing grease, @. DSHELL ALVAANIA GREASE RO and ESSO BEAGON2 (all O-rings) F Cilall sealing) Looking fluid + high locking forea, e.g. LOCTITE 275, 270 and TRULOC 397, 280+ + all pligs except pressure measuring plug = 2 -DNS Co., Ltd. DNB D25iIls DN B D25is