SECTION IV MAINTENANCE & ADJUSTMENTS Section IV -- Page # 1 DAILY BREAKER INSPECTION F1 through F5 Hammers WARNING:
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SECTION
IV
MAINTENANCE & ADJUSTMENTS
Section IV -- Page # 1
DAILY BREAKER INSPECTION F1 through F5 Hammers WARNING:
Any maintenance should be done in a safe, obstructionfree environment.
The following is a list of items should be inspected on a daily basis:
A) Item:
Loose, missing or damaged nuts and bolts
Location:
Accumulator cover mounting bolts Top cover bolts and nuts 1 Retainer and stop pins 2 Through bolts and nuts Frame cross bolts and nuts 7
Remedy:
Re-torque according to the torque specification page in this manual.
B) Item:
Missing rubber plugs, GPF and screw plugs
Location:
Fronthead, Grease port 2,6
Remedy:
Replace
Section IV -- Page # 2
C) Item:
Loose or damaged hydraulic lines
Location:
Pressure and return lines for the breaker 3
Remedy:
Tighten any loose fittings Replace any damaged hoses or piping
D) Item: Location:
Abnormal oil leakage at lower end of breaker 4 Connection between the backhead, cylinder and front head Clearance between the working steel and front cover
Remedy:
Breaker should be re-sealed Contact your dealer
E) Item:
Abnormal wear on the working steel
Location:
Working steel 5
Remedy:
All burrs should be removed with a grinder If the point is worn, reshape with a grinder (Refer to the WORKING STEEL" section of this manual)
F) Item:
Grease
Location:
Front head 6
Remedy:
Grease at the start and every 2 to 3 hours of operation 5 to 10 pumps from a hand grease gun is recommended with the working steel pushed up into the breaker
G) Item:
Fluid level and contamination of hydraulic oil
Location:
Oil Reservoir, Filters
Remedy:
If fluid level is low, fill per manufacturer's specifications To inspect for contamination, refer to the "HYDRAULIC FLUIDS and GREASES" section of this manual.
To maintain the optimum performance from the breaker, it is recommended that a complete inspection and maintenance be done periodically.
Section IV -- Page # 3
HYDRAULIC FLUIDS and GREASES F1 through F5 Hammers
The life-blood of the breaker is the hydraulic oil. In order to maintain peak performance from the breaker, it is essential to use the correct oil as well as maintain a clean hydraulic system. SELECTION OF HYDRAULIC OIL To select the proper oil, refer to the following table: MANUFACTURER
ISO VG 68 ( HOT WEATHER )
ISO VG 46 (COLD WEATHER)
( EXTREME COLD )
SHELL ESSO MOBIL
TELLUS OIL 56 NUTO H68 DTE 26
TELLUS OIL 46 NUTO H46 DTE 25
DTE 13
** NOTE: IF A PHOSPHATE ESTHER FLUID IS USED, SPECIAL SEALS ARE REQUIRED. CONSULT YOUR FURUKAWA ROCK DRILL USA REPRESENTATIVE. HYDRAULIC OIL CONTAMINATION Oil contamination can result in malfunctions and unsatisfactory performance of both the hydraulic breaker and the base machine. Special attention must be paid to the hydraulic system. The hydraulic system of the base machine may become contaminated faster when using a breaker than when using a bucket or other attachment. The following guidelines should be followed when using a hydraulic breaker: •
When installing the breaker onto a machine for the first time, drain the hydraulic system of the base machine completely. Flush the reservoir, cylinders and piping as thoroughly as possible. Replace the main line oil filter cartridge. Add new hydraulic oil. If the base machine is brand new, this step may be omitted.
•
The main return filter element should be replaced after the first 50 hours of operation and every 125 hours thereafter.
•
Change the hydraulic oil after the first 250 hours of operation and every 600 hours thereafter or sooner in accordance with the carrier manufacturer’s specifications.
•
Normal oil temperature should be maintained between 100°F and 140°F during hammer operation. CAUTION: Do not operate the hydraulic breaker if the oil temperature exceeds 176°F. Operation at such temperatures would substantially shorten the life of the breaker.
Section IV -- Page # 4
•
Oil contamination should be kept to ANAS NO.9 class. Field determination of contamination is as follows: Place a sample of the base machine's hydraulic oil in a transparent container. Also place a sample of unused oil in another transparent container. Compare the two containers. If there is a visual difference in the color, the base machine's oil is presumed to be contaminated. GREASE Furukawa Rock Drill USA's small “F” Series hydraulic breakers are equipped with one (1) grease fitting. This fitting is located on the front bushing, down by the working steel (refer to the illustration below). Lack of lubrication can cause failure of the working steel, piston or shorten the life of the seals. An NLGI NO.2 grease is recommended. The following is a list of the recommended greases: SHELL ALVANIA EP2 ESSO LITHTAN EP2 MOBIL MOBILPLEX 48
•
The fronthead should be lubricated every 2 - 3 hours of operation. Grease more frequently, if needed, but do not over-load the tool with grease.
•
When greasing the hammer, hold it in an upright, vertical, position, being sure that the working steel is fully engaged into the chuck.
•
Avoid getting rock or cement chips into the fronthead when replacing working steels. Particles which may have adhered to the grease can cause scratches and scaring inside the hammer. Section IV -- Page # 5
SECTION V TORQUE SPECIFICATIONS & BREAKER WEAR LIMITS
Revised April, 2010 Section V -- Page 1
TORQUE SPECIFICATIONS F1 ~ F5 Hammers
Note: Some external box, plates, or weldments have been removed for clarity. This drawing is representative of a number of models and might not match your hammer.
;
As a general rule, all bolts should be torqued in sets, so that the load is divided equally among any bolts that function as a group. Torques listed refer to lubricated threads. Apply anti-sieze compound to all threads, nuts, and washers prior to assembly. All bolts in a group should first be loosened, and then re-tightened in stages, alternately bringing opposing bolts up to the same torque level, until all bolts in the group share the load equally. Continue in the same way, bringing all bolts in that group up to the final torque level specified.
Section V -- Page 2
TORQUE SPECIFICATIONS F1 Series Hammers
1) Through Bolt Hex Nut
Torque: 180 ft-lbs. (25 kg-m) Every 50 hours of operation
2) Accumulator Cover Bolts
Torque: 180 ft-lbs. (25 kg-m) Every 100 hours of operation
3) Accumulator Plug
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
4) Accumulator Cap
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
5) Cross Bolts (Upper & Lower)
Torque: 130 ft-lbs. (18 kg-m) Every 100 hours of operation
Revised April, 2010 Section V -- Page 3
TORQUE SPECIFICATIONS F2 Series Hammers
1) Through Bolt Hex Nut
Torque: 250 ft-lbs. (35 kg-m) Every 50 hours of operation
2) Accumulator Cover Bolts
Torque: 180 ft-lbs. (25 kg-m) Every 100 hours of operation
3) Accumulator Plug
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
4) Accumulator Cap
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
Top Cap Bolts (Qt & FSP Models)
Section V -- Page 4
Torque: 95 ft-lbs. (13 kg-m) Every 100 hours of operation
TORQUE SPECIFICATIONS F3 Series Hammers
1) Through Bolt Hex Nut
Torque: 325 ft-lbs. (45 kg-m) Every 50 hours of operation
2) Accumulator Cover Bolts
Torque: 180 ft-lbs. (25 kg-m) Every 100 hours of operation
3) Accumulator Plug
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
4) Accumulator Cap
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
Top Cap Bolts (Qt & FSP Models)
Torque: 200 ft-lbs. (28 kg-m) Every 100 hours of operation
Revised April, 2010 Section V -- Page 5
TORQUE SPECIFICATIONS F4 Series Hammers
1) Through Bolt Hex Nut
Torque: 400 ft-lbs. (55 kg-m) Every 50 hours of operation
2) Accumulator Cover Bolts
Torque: 180 ft-lbs. (25 kg-m) Every 100 hours of operation
3) Accumulator Plug
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
4) Accumulator Cap
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
5) Cross Bolts (Upper & Lower)
Torque: 380 ft-lbs. (52 kg-m) Every 100 hours of operation
Top Cap Bolts (Qt & FSP Models)
Section V -- Page 6
Torque: 330 ft-lbs. (45 kg-m) Every 100 hours of operation
TORQUE SPECIFICATIONS F5 Series Hammers
1) Through Bolt Hex Nut
Torque: 540 ft-lbs. (75 kg-m) Every 50 hours of operation
2) Accumulator Cover Bolts
Torque: 250 ft-lbs. (35 kg-m) Every 100 hours of operation
3) Accumulator Plug
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
4) Accumulator Cap
Torque: 60 ft-lbs. (8 kg-m) Every 100 hours of operation
5) Cross Bolts (Upper & Lower)
Torque: 560 ft-lbs. (77 kg-m) Every 100 hours of operation
Top Cap Bolts (Qt & FSP Models)
Torque: 330 ft-lbs. (45 kg-m) Every 100 hours of operation
Revised April, 2010 Section V -- Page 7
WEAR LIMIT DIMENSIONS FOR REPLACEMENT PARTS Front bushing (F1 ~ F9)
Measurement at a location 0.38" (10 mm) from the edge.
Model
Bore(A) of new
Wear limit of bore
Bore(A) of new
US (Inches)
Wear limit of bore
Metric (mm)
F1
－
－
F2
1.772
1.850
45
47
F3
2.047
2.126
52
54
F4
2.362
2.441
60
62
F5
2.677
2.835
68
72
F6
2.953
3.110
75
79
F9
3.543
3.701
90
94
Front cover (F12 ~ F70)
Measurement at a location 0.38" (10 mm) from the edge.
Model
Bore(A) of new
Wear limit of bore
F12
4.134
4.370
105
111
F19
4.724
4.961
120
126
F22
5.315
5.551
135
141
F27
5.512
5.748
140
146
F35
5.906
6.220
150
158
F45
6.496
6.811
165
173
F70
7.086
7.401
180
188
Bore(A) of new
US (Inches)
Section V -- Page 38
Wear limit of bore
Metric (mm)
Piston (F1~ F5)
Model
Dimension(A) of new part
Wear limit dimension (B)
Dimension(A) of new part
US (Inches)
Wear limit dimension (B)
Metric (mm)
F1
1.378
1.339
35
34
F2
1.378
1.339
35
34
F3
1.772
1.732
45
44
F4
1.969
1.929
50
49
F5
2.087
2.047
53
52
Wear limit dimension (B)
Dimension(A) of new part
Wear limit dimension (B)
Piston (F6 ~ F70)
Model
Dimension(A) of new part
US (Inches)
Metric (mm)
F6
.591
.551
15
14
F9
.591
.551
15
14
F12
.787
.728
20
18.5
F19
.787
.728
20
18.5
F22
.984
.925
25
23.5
F27
.984
.925
25
23.5
F35
.984
.925
25
23.5
F45
1.181
1.122
30
28.5
F70
.590
.531
15
13.5
Section V -- Page 44
Rod Pin (F1 ~ F9)
Model
Dimension(A) of new part
Wear limit dimension (B)
Dimension(A) of new part
US (Inches)
Wear limit dimension (B)
Metric (mm)
F1
.787
.709
20
18
F2
.984
.906
25
23
F3
.984
.906
25
23
F4
1.181
1.102
30
28
F5
1.378
1.260
35
32
F6
1.181
1.102
30
28
F9
1.378
1.260
35
32
Dimension(A) of new part
Wear limit dimension (B)
Dimension(A) of new part
Wear limit dimension (B)
Rod Pin (F12 ~ F70)
Model
US (Inches)
Section V -- Page 40
Metric (mm)
F12
2.165
2.047
55
52
F19
2.756
2.638
70
67
F22
3.150
3.031
80
77
F27
3.346
3.228
85
82
F35
3.543
3.386
90
86
F45
3.937
3.780
100
96
F70
4.724
4.566
120
116
Working Steel (F1 ~ F45)
Model
Effective length(A) of new part
Wear limit effective length (B)
Effective length(A) of new part
US (Inches)
Wear limit effective length (B)
Metric (mm)
F1
10.236
7.283
260
185
F2
11.417
8.465
290
215
F3
12.795
8.865
325
225
F4
13.780
9.449
350
240
F5
14.646
9.921
372
252
F6
17.717
12.205
450
310
F9
19.685
13.780
500
350
F12
25.591
13.780
650
350
F19
27.559
14.961
700
380
F22
28.543
15.945
725
405
F27
29.528
16.929
750
430
F35
30.512
17.913
775
455
F45
31.496
18.898
800
480
F70
33.858
21.259
860
540
Revised April, 2010 Section V -- Page 43
SECTION
VI
CHARGING PROCEDURES
Section VI -- Page # 1
F SERIES HAMMER GAS CHARGE SERVICE KIT INFORMATION
Section VI -- Page # 2
F SERIES HAMMER GAS CHARGE SERVICE KIT INFORMATION UNIVERSAL CHARGE KIT PART NO. KBM21805 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PART NO.
QTY
K15587 K03034 K15588 K01829 K21806 K08897 K08977 K15341 K15340 K15350 K15351 K15348 K04692 K15339 K21373 K15331 K15659 K15374 K19799
1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 * * 1 1
DESCRIPTION CHARGE KIT ADAPTER O-RING CHARGE KIT ADAPTER O-RING HOSE ASSEMBLY 1/4" NPT FEMALE TEE 1/4" NPT PIPE NIPPLE 1/4" NPT Q.D. NIPPLE 1/4" NPT Q.D. COUPLER 200 PSI PRESSURE GAUGE 1000 PSI PRESSURE GAUGE 1/4" NPT SHUT-OFF VALVE 1/4" NPT X 4 JIC ADAPTER 4 JIC CAP HOSE ASSEMBLY CHARGE ADAPTER 1/8" NPT X 4 JIC ADAPTER 4 JIC SWIVEL ELBOW 1/4" NPT X 1/8" NPT ADAPTER
Please note that the nitrogen gas tank and regulator/gauges set are not included in the KBM21805 Charge Kit. The gas tank can be any convenient size, and is readily available from most local welding gas suppliers. The Regulator/Gauge Set should be one that is appropriate to 1000 psi applications, similar to those referred to as "Argon" sets. A Furukawa Rock Drill USA K15590 Regulator/Gauge Set is available for use with the KBM21805 Charge Kit, but Furukawa Rock Drill USA does not supply gas or gas tanks. •
The K15331 Charge Adapter is no longer used, but may be ordered separately for those older hammers that use the Schrader-type valve. The K15659 Fitting is required for use with this kit.
Section VI -- Page # 3
ACCUMULATOR CHARGING PROCEDURE To receive the optimum performance from the hydraulic breaker, care must be taken to maintain the proper nitrogen charge in the accumulator of the breaker. To assist with this, Furukawa Rock Drill USA can supply a charge kit as illustrated on the opposite page. The following is a step-by-step procedure that should be used to properly charge the accumulator. (Note: These instructions are written for Furukawa Rock Drill USA's charge kit. If you are not using Furukawa Rock Drill USA's charge kit, use the same procedure only disregard the reference to item numbers. STEP 1
The breaker should be charged at ambient temperature (not operated).
STEP 2
The customer must supply a nitrogen tank complete with a regulator.
!
USE EXTREME CAUTION WHEN HANDLING PRESSURIZED VESSELS!!
STEP 3
Connect hose assembly (15) to the regulator on your nitrogen tank.
STEP 4
Turn shut-off valve (12) clockwise until completely closed.
STEP 5
Connect the 0-1000 PSI pressure gauge (11) and Q.D. coupler (9) to the Q.D. nipple (8).
STEP 6
Adjust your regulator to its lowest setting before opening the valve on your nitrogen tank. Open the valve on your tank and adjust your regulator to the appropriate accumulator charge. (Refer to the table shown on Page 24 to select the appropriate charge. A pressure closest to the middle of the range specified is optimum.)
STEP 7
Remove the external plug located in the accumulator charge port on top the accumulator. Screw charge adapter (3) with O-ring (4) into the charge port.
STEP 8
Attach hose assembly (5) to charge adapter (3).
STEP 9
Remove the protective cap (19) from the accumulator, and loosen the valve (21) approximately one turn.
STEP 10
Open shut-off valve (12) to allow the gas to enter the accumulator chamber.
STEP 11
Wait about 15 seconds. The pressure reading on gauge (11) should now be correct. If the reading is not the proper charging pressure as shown in the table, adjust your regulator accordingly. Once the correct pressure reading is achieved, turn the shut-off valve (12) clockwise until it is fully closed.
STEP 12
Tighten the valve (21) completely, and replace the protective cap (19).
STEP 13
Remove charge adapter (3) from the charge port.
STEP 14
Re-install the plug into the charge port.
Section VI -- Page # 4
BACKHEAD PRESSURE TABLE NITROGEN GAS CHARGE PRESSURE Ambient Temperature 90° ~ 100° F 80° ~ 90° F 70° ~ 80° F 60° ~ 70° F 50° ~ 60° F 40° ~ 50° F 30° ~ 40° F 20° ~ 30° F 10° ~ 20° F 0° ~ 10° F -10° ~ 0° F
KHB1G & KHB2G
KHB3G to KHB30G
39 38 37 36 35 35 34 33 32 31 31
89 - 106 PSI 88 - 104 PSI 86 - 102 PSI 85 - 101 PSI 83 - 99 PSI 82 - 97 PSI 80 - 95 PSI 79 - 93 PSI 77 -93 PSI 76 - 90 PSI 75 - 88 PSI
-
52 51 50 49 48 47 46 45 44 43 42
PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI
KHB40G & KHB50G 131 129 127 125 123 121 119 117 115 113 111
-
154 151 148 145 142 139 136 133 130 127 124
PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI
All F Series Hammers 145 – 150 PSI 143 - 148 PSI 141 – 144 PSI 138 – 142 PSI 136 – 139 PSI 132 - 137 PSI 130 – 133 PSI 128 - 131 PSI 124 – 128 PSI 122 - 125 PSI 119 - 122 PSI
ACCUMULATOR PRESSURE TABLE Ambient Temperature 90° ~ 100° F 80° ~ 90° F 70° ~ 80° F 60° ~ 70° F 50° ~ 60° F 40° ~ 50° F 30° ~ 40° F 20° ~ 30° F 10° ~ 20° F 0° ~ 10° F -10° ~ 0° F
Section VI -- Page # 6
NITROGEN GAS CHARGE PRESSURE All G Series Hammers 732 719 706 693 680 666 653 640 626 613 600
-
810 796 781 767 753 739 725 710 696 682 668
PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI
All F Series Hammers 908 - 956 PSI 892 – 924 PSI 876 - 908 PSI 860 - 892 PSI 844 – 876 PSI 828 – 860 PSI 812 – 844 PSI 796 – 828 PSI 780 – 812 PSI 764 – 796 PSI 748 - 780 PSI