Maruzen BH20EV Operating Manual

Download

FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY

BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES

OPERATING PROCEDURES WILL CAUSE DAMAGES TO THE MACHINE.

ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.

HYDRAULIC HANDHELD BREAKER

MODEL BH20EV

OPERATING MANUAL

MARUZEN KOGYO CO., LTD.

CAUTION

(Nov 20, 2015)

FOREWORD

This manual is an important part of your equipment. It provides rules and guidelines which will help you use this machine safely and effectively. You MUST familiarize yourself with the functions and operations by reading the manual thoroughly before you begin using this machine. For your safety, it is especially important that you read and observe all precautions in this manual and labels on the machine. The precautions MUST be followed strictly at all times when performing operation and maintenance. * Fail to follow the guidelines and safety alerts in the manuals and on the machine, or use this machine in alternative ways from the manuals may result in system failure or serious personal injury.

Keep this manual with the equipment or in an easily accessible place in all times for future reference. Make sure all personnel involved in working on this machine can consult it periodically. In case this manual should be lost or damaged, immediately contact us or your dealer to purchase a new copy.

We recommend you always use Maruzen genuine components and parts. Replacing components and parts from other sources may cause damages to this machine and endanger operators.

MARUZEN KOGYO CO., LTD.

155-8 NAGABUSE, MISHIMA-SHI,

SHIZUOKA-KEN, 411-0824, JAPAN

CONTENTS

Safety Information .............................................................. 4 ～ 7

Safety Alert Classifications ........................................... 4

Safety Alerts .................................................................. 5 ～ 7

Introductions ....................................................................... 8

How To Adjust the Hammering Power ............................... 8

Specifications & Descriptions ............................................. 9

Precaution Labels and Positions ........................................ 10

Inspection before Each Operation ...................................... 11

Guidelines ........................................................................... 12 ～ 13

Operation............................................................................. 14 ～ 15

Daily Check Out .................................................................. 16

Periodically Inspection ....................................................... 16

Available Tools .................................................................... 16

Troubleshooting ................................................................... 17～ 18

Exploded View ................................................................... 19

Parts List ............................................................................. 20 ～ 21

SAFETY INFORMATION

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.

SAFETY ALERT CLASSIFICATIONS

The following safety alert symbols are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machines labels, the following safety alert symbol are used to express the potential level of hazard.

** Safety alert symbols are to emphasize all operation which, if not

strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

DANGER

Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

DO NOT OPERATE THE MACHINE UNLESS THE FOLLOWING SAFETY

INSTRUCTIONS HAVE BEEN THOROUGHLY READ AND UNDERSTOOD!

Do not operate the equipment if you are or if your

1. taking medication, feeling drowsy, feeling unwell or feeling tired.

2. under the influence of drugs or alcohol.

3. hands, feet, lower back or other parts of your body hurt or being injured.

* Failure to observe this precaution can result serious injury or even death.

WARNING

Before operating the equipment, be sure to ware personal protective equipments such as follows:

1. Helmet

2. Protective goggles

3. Protective boots

4. Safety gloves

5. Hearing Protection

SAFETY ALERTS

CAUTION

Do not touch the machine with your bare hands

1. The oil tank may become hot under continuous running

Do not touch the equipment with your bare hands.

2. Tools may become hot under continuous use, make sure to ware gloves before any contact with the tools.

* Failure to observe this precaution can result getting burned

CAUTION

When lending someone the equipment

Make sure the safety instructions have been thoroughly read and fully understood by the person who is going to use the equipment.

WARNING

Avoid Blank Hammering

Operating the equipment horizontally may cause the chisel’s sudden flying out. Excessive blank hammering may be considered equipment abuse and may cause equipment damage.

Failure to observe this precaution can result damage to the breaker.

WARNING

Never operate the breaker when bystanders are in the work area

1. Do not operate the breaker if any people are within the area where flying debris or movement of the breaker may injure them.

2. For preventing flying debris, make sure protection fences are being set up.

Failure to observe this precaution can result personal injury.

WARNING

Be special cautions to high pressure gas

1. High pressure gas was held inside the accumulator of the breaker.

2. Do not loosen the nut unless it is necessary for

maintenance.

Failure to observe this precaution can result serious injury

INTRODUCTION

1. This hydraulic breaker is designed to be used for the following purposes.

(1) Breaking concrete and asphalt (2) Digging or breaking hard soil (3) Compacting soil (4) Cutting asphalt

2. DO NOT operate this breaker on the following situations:

(1) Drench part of the breaker or whole breaker into water or

seawater.

(2) Connect with power source which its oil flow and pressure exceeds

the range prescribed.

(3) Operating at oil temperature below 10℃ or over 90℃. (4) Using with the other not genuine tools (5) Operation below 10°C or over 40°C. (6) Use the equipment for purposes other than stated in this manual.

If you want to use this breaker in other conditions except above, always consult with us.

SPECIFICATIONS & DESCRIPTIONS

Weight 20kg (Without tool)

Dimensions L665mmxW410mm

Working Pressure 8 ～ 11 MPa

Max. Pressure 20.6 MPa

Oil Flow 20.5l B.P.M. 1450bpm

Shank Size Hex. 1” x 108mm

Coupling 3/8” Couplers

Back Pressure 2.5MPa

Extension Hose 3/8” x 10m (with Power Unit)

Hydraulic oil ISO VG32, VG40 or equivalent

NOISE 84.3 dB(A)

Vibration 8.56c/sec2

Latch

Safety Labels

Part No. Part Name ①

MPL1Z074A

Label BY（warning）

②

MPL1Z075A Label BZ (warning)

INSPECTIONS BEFORE EACH OPERATION

Inspection Items Countermeasures

1. Loose nut

Tighten the loosen nut

2. Loose of plug

Tighten the plug

3. Loose of bolts

Tighten the bolts

4. Loose of hose fittings

Tighten the fittings

5. Wears of handle

grips

Replace new one

6. Crack of control

lever

Replace new one

7. Damage of hoses

Replace new ones

8. Oil leakage of

each parts

Replace the seals

9. Damage of tool Replace the tool

10. Loose of tool

Check the latch and replace if necessary

For the purpose of keeping the breaker in good condition, make sure the

following items should be inspected each time before using. (Refer the drawing below)

GUIDELINES

1. Always use Maruzen Genuine Tools. Use other than Maruzen genuine tools may cause breakage of tools which may lead to the damage of the breaker and personal injury.

2. Consult with us when using power source other than UH070 Maruzen power pack.

3. When connecting and disconnecting couplers, make sure dirt, dust and other foreign substance does not enter or attach to couplers and hoses.

4. Make sure the power source is OFF when connecting the breaker to the power source. Or changing tools (Moil point etc)

5. Maruzen original tools are highly recommended. Consult your dealer for more specifics of tools.

6. If the oil temperature is below 10℃, warm up the breaker before start operating.

7. Pay attention to the followings while operating the breaker. (1) Be cautious for not being injured by the front of the tool. (2) Be cautious for not being tripped by the extension hoses. (3) Make sure there are no obstacles at jobsite. (Be cautious not

being tripped by obstacles while operating)

(4) While pulling out the breaker from the broken objects, be

cautions for not being fall over.

(5) Make sure the breaker was placed in horizontally. Fail to

place the breaker horizontally after operating can cause injury by sudden falling of the breaker.

(6) Be cautious not to injure your back while lifting the breaker.

8. In case of sudden hydraulic hose breakage and hydraulic oil belch out. STOP the power source IMMEDIATELY.

9. Replace new hoses when they are worn or when oil exudes from them.

10. When detach couplers, a small amount of oil may slip out. Make sure that surrounding area does not get dirty by oil.

11. When detach from power source, attach two hoses to each other.

CAUTION

12. When frequently attach and detach to the power source, hydraulic oil will decrease accordingly. Always make sure the hydraulic oil level before operating and refill if necessary.

13. After the operation, use tool to push up the piston.

14. If the oil temperature is below 10℃, warm up the breaker before start operating.

15. For long-term storage:

1) Connect breaker to hydraulic power pack, insert any wood bar (∅20～25mm, L 350mm) into front end to push up piston to the end.

2) Apply antirust on piston.

3) Apply oil all over breaker with wet cloth. Cover it properly and make sure it is kept in a low humidity place.

4) Remove plug on front end and attach grease nipple for applying grease.

Immediately STOP the power source if the breaker does not stop after releasing the control lever. Ask Maruzen dealer for repair and service before the next operation.

OPERATION When connect this breaker to power source other than Maruzen UH070 power unit, make sure the power source you intend to use is within the range (oil flow, pressure etc) prescribed on page 9.

Preparation

1. Unlock the latch on the breaker and insert tool (moil point etc) Turn around the tool(Hexagon tool) if it stuck on the half way of inserting.

2. Lock the latch. Make sure the tool is firmly fastened.

CAUTION

Tool

Latch

3. Make sure there is no dust or dirt inside couplers before connecting breaker to hydraulic power pack.

4. Active the power source. (Start the engine on the power pack)

Operation

5. The breaker and the breaking object should be on a right angle. Press down the breaker with your body weight. Grip the control lever and start hammering.

Breaker Hoses

Couplers: Make sure they are

clean before the attachment

Extension Hoses

Right angle to the breaking

target

Start Hammering

6. Do not hammer the same place for over 30 seconds. If the target object does not break within 30 seconds, change the hammering point.

7. Do not blank hammering for over 10 seconds.

8. Stop the power pack when the job has completed.

9. Push up the tool so the piston return to the position.

10. Detach the extension hoses.

11. Attach both couplers which are on the breaker together to prevent dust and dirt entering.

12. Unlock Latch, remove tool from the main body.

13. Remove mud and dirt on breaker thoroughly.

DAILY CHECK OUT

Check before each operation

1. Check if there is any oil leakage from hoses or breaker itself.

2. Check if there are any cracks or damage in tools.

PERIODICAL INSPECTION

Ask your dealer for the periodical inspections.

Inspection Items

Operating Hours

Nitrogen gas charge in accumulator

300 hours or 1 Year

Replacement of accumulator diaphragm

500 hours or 2 years

Replacement of Valve Rod O ring

500 hours or 2 years

Replacement o

f U-cup packing

500 hours or 2 years

Replacement of each O Ring

Every 3 years

Wear of Movable Bush

Every 250 hours or every year

Grease Movable Bushy

(8g)

Every 50 hours

* Accumulator Nitrogen gas pressure: 3.5MPa (35.7kgf/㎠)

AVAILABLE TOOLS

MOIL POINT

For Breaking

CONCRETE CHISEL

For Breaking

ASPHALT CHISEL

For Cutting Asphalt

SHOVEL

For Digging Hard Soil

TAMPING RAMMER

For Compacting Soil and Sand

L = 400mm

Symptoms Causes Countermeasures

Grip the control lever but does not

start

1. Power so

urce is off (Switch lever is

in OFF position)

2. Hoses are not connected

3. Couplers are not connected properly

4. Relief valve pressure is set too low

5. Damage of control valve

6. Control valve is stuck by foreign substances

7. High pressure side and oil return side was connected inversely

1. Start the power source (Turn the

switch lever to On position)

2. Connect hoses

3. Check out if all the couplers have been connected properly

4. Adjust pressure to 140～210kgf/㎠ (13.7～20.6MPa) *

5. Replace a new control valve *

6. Disassemble breaker, clean and

remove dirt and dust between control valve and valve body *

7. High pressure hoses is connected to

the upper side of the breaker

Functionin

g but weak hammering or low

hammering speed

1. Low rate of oil flow from power

source

2. Pressure in relief valve in power source is set too low

3. Control valve does not function properly

4. Back pressure is too high

1. Turn the engine rotation rate up and

increase the rate of oil flow (Adjust oil flow to the necessary rate)

2. Check displacement of hydraulic pump*

3. Adjust pressure to the range of 11.7 ～20.6MPa) *Remove and clean the joint of control valve and valve body *

4. Use widen or shorter hose on the oil

TROUBLE SHOOTING

5. Moveable Bush got stuck

returned side to lower the back

pressure to 2.5MPa or under.

5. Disassemble and clean the breaker*

Hammering in normal speed, but week

hammering

1. Low accumulator gas pressure

2. Damage of accumulator diaphragm

3. Temperature of hydraulic oil is abnormally high.

1. Refill Nitrogen ga

35.7kgf/㎠ (3.5MPa) *

2. Replace diaphragm *

3. Check power source. Clean radiator and fan

Strong hammering and in high speed

1. High rate of oil flow

1. Turn the engine rotation rate down

to decrease the rate of oil flow (Adjust oil flow to the right range)

The breaker stops hammering during

operation

1. Couplers are not connected

2. Damage of control valve

1. Check each connected parts

2. Replace a control valve *

Oil leakage from control lever

1. Damage, wear or harden of O ring

1. Replace O ring

Profuse

Oil leakage from front end

1. Damage of U cup pack

ing

2. Damage of U cup packing due to the scratch of piston rod.

1. Replace U cup packing

2. Replace U cup packing, remove the scratch on piston rod *

Latch is nearly coming off

1. Damage of lock spring

2. Ware of latch

1. Replace lock spring

2. Replace latch *

High pressure hose shakes intensely

1. Damage of accumulator diaphra

gm 1. Replace diaphragm

Release

the control valve but the breaker

does not stop

1. Foreign substance is caught in the

valve rod

1. Disassemble, clean and adjust *

For items with *, ask Maruzen dealers for service and maintenance.

EXPLODED VIEW MODEL BH20EV

Ｎｏ．

Part No. Part Name Q’ty

Ｎｏ．

Part No. Part Name Q’ty

MB19Z010A Cover

1 22

MB02E006A Diaphragm

MB19Y001B Cover

2 23

MB19Y002A Shell

MB35Z009A

Handle (Ｌ）

1 24

WS－06<<<<<<<<BH

Seal Washer

MB19Z023B

Handle (Ｒ）

1 *25

1120―413―D Cap Bolt

1120―414 Handle Grip

2 26

OS－15

O-Ring

MB35Z010A Control Lever

1 27

MB35Z017A Plug

MB19Z016A Lever

1 28

OBP－22

Back up Ring

MB19Z008B Pin

2 29

OP―22 O-Ring

MB19Z035A Washer

2 *30

MB32X002A Valve Body

MB19Z021A Pad

2 31

M2LTE120Ａ M6 Orifice(φ2.6）

MB19Z006A Pin

2 32

BH―8×70（Zn）

Bolt

MB19Z024B Washer

2 *33

MB32Z003A Valve Bush

MB19Z020A Spring Washer

2 34

M1XTE108A Control Valve

MB19Z007A Spring

2 35

M1HTE107A Spring (P)

MB19Z019A Spring Washer

2 36

QB－5／16

Steel Ball

SH―5x8（Togarisaki）

Stopper Screw

4 *37

MB32Z004A Inner Tube (V)

BH―6×12 Bolt

2 38

MB19Z009A Through Bolt

MB19Z030A Guide Bush

2 39

WS－18<<<<<<<<BH

Seal Washer

K5Ⓑ1620

DU Bush

2 40

21091・3-35--

Hose

MB19Z011A Lid

1 41

21091・3-50--

Hose

CO―0644 O-Ring

1 42

QC―03M Coupler ( Male)

No.

Part No. Part Name

Q’ty No.

Part No. Part Name Q’ty

QC―03F Coupler ( Female)

1 64 1110―410

Lock Spring

MB19Z014A Push Rod

M1KTE173A

Lock Pin

OBP―14 Back up Ring

MB37Z001A

Ring

OP―14 O-Ring

1 67

BPH1―PT1／8

Plug

*47

M2LTE108A Valve Guide

1 68 GN―01

Grease Nipple (Accessory)

OP－12.5

O-Ring

1 *80 MB37X015A

Front End (K)

49 OBP―5

Back up Ring

1 81

1110－402

Latch

50 OP―5

O-Ring

1 *82 MB37Z012A

Fixed Bush

*51 M1KTE111A

Valve Rod

1 83 MB37Z011A

Spring

52 MB18Y046A

Piston

1 84 MB37Z013A

Movable Bush

53 OG-60

O-Ring

1 85 MB37Z014A

Washer

54 PR―6x20

1 86

MZ42－002D

Moil Point (Accessory)

*55 M1XTD104B

Cylinder (A)

56 MB850―040

Expander

57 MB29Z023A

Maruzen Sticker 2

IUIS 30、40、6 U Cup Packing

LBI 30、38、5、6.5

Dust Seal

60 WF―14 2L

Washer

61 1120―423

Nut

62 PR―16×60

63 PR―10×60

No. Code Descriptions Q’ty

Ａ1

MB19Z051A

Accumulator Assy

20、21、22、23、24、25、26、27、28、29

Ａ2

MB24Z509A

Cap Bolt Assy

24、25

Ａ3

MB35Z075A Plug Assy 1

26、27

Ａ4

MB32Z500A

Valve Body Assy

30、31、33、67（4）

Ａ5

M2LTZ506A

Valve Guide Assy

45、46、47、48

Ａ6

M1XTZ505A

Valve Rod Assy

49、50、51

Ａ7

MB32Z501A

Inner Tube Assy

35、36、37、67

Ａ8

MB35Z501A Handle (L) Assy 1

3、5、8、10、11（2）、16（3）

Ａ9

MB19Z040A

Handle（R）Assy

4、5、8、10、16

Ａ10

MB19Z044A Cover Assy 2

2、19

Ａ11

MB19Z052A Cylinder Assy 1

55、56（1）、67（4）

Ａ12

MB37Z502A Front End (K) Assy 1

67、80、82

A13 MB19Z039A Seal Kit 1

21、24、26、28、29、39（2）、45、46、48、49、50、53、58、

Maruzen BH20EV Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual