- Operation Manual EVOL U UC ELCs RHB3 SERIES =—=s—_—s«s(({. HANWO Muttiquip Corp.ele SYN lkPay particular attention to ail safety messages. Contamination of hydraulle oll can damage main hydraulic components, such as working pumps or motors, and control valves. Check nitrogen (N2) gas pressure regularly. ‘The blow power reduces if gas pressure falls below specification. This manual contains full instructions, on safe Hanwoo hammers operation and maintenance. Please study this manual before installing, operating or maintaining this equipment. Do not operate manual. ‘equipment before you have read and fully understood this Back-head gas Is not charged. - Charge Back-head nitrogen (N2) gas before use. Attached CAUTION sticker (Accumulator is not charged.) on Accumulator charge plug. ~ In case of air travel, Nitrogen (N2) gas must be discharged. = Remove warning sticker. = Charge Accumulator Nitrogen (N2) gas before use.Table of Contents + Foreword 4, Sate Operation 2. Hammer Specifications 2.1. Specifications of RHB301/302/309/305 2.2, Specitications of RHB319/322/926/332 - 3. Structure 3.1, Power Call - 4. Working Principle 4.1, Working Principles for RHB301/302/309/305 models «+--+ 4.2. Working Principles for RHB319/322/326/332 models 5. Pipe lines es Setiattisaeiiioniae 6. Hammer Installation and Removal 6.1, Hammer Installation 6.2, Hammer Removal: 7. Chisel Installation and Removal 7.1. Chisel installation (RHB901/302/303/305) Chisel Installation (RHB313/322/328/332) 7.2, Chisel Removal (RHB301/302/903/308) --- Chisel Removal (RHB319/322/328/332) 8. Pre-Checks before Operation 8.1, Checking Stop valves - 22 8.2. Checking Nitrogen(N2) gase+s+++ z 22 8.3. Checking Hydraulic oil se - 22-23 8.4, Checking Grease - 24 8.5. Bolt and nut Torque specifications +25 8.8. Operating Temperatures +++ a 26 8,7. Cooling +++ 9. Maintenance-- 9.1, Maintenance Intervals +++ Evory 2 Hours Every 10 Hours, or Daily Every 60 Hours, or Weekly Every 100 Hours, or Monthly Every 600 Hours, or Annually 9.2. Nitrogen(N2) gas Charging and Release Buckhead gas Pressure Release 29 Buckhead gas Pressure Charging: + 30 Accumulator gas Inspection and Charging seen BH 9.5. Through Bolt Inepection and Replacement -- 329.4, Seal Inspection and Replacement z 93 9.5. Chisel and Chisel Bush Wearing Inspection co 84 10. Trouble Shooting se 35 11. Chisel Claim judgment 141.1. Breakage of piston striking point or of chisel pin contact comers - 11.2. Plastic deformation of piston striking point 11.3. Breakage inside basic line 87-38 11.4, Breakage outside basic line « 38-99 14.5, Crushing of chisel tip ~ 7 + 40 14.6. Chisel tip wear. --sssseeeeee a + Parts List a 7 atForeword This manual contains safety, operation, lubrication, and maintenance information, ‘The manual Is a reference document for new operators, and a refresher document for experienced personnel. Read, understand, and store it close to hammer. ‘Some photographs or illustrations In this publication may show details that differ from your hammer. For example, a bracket may have been removed for purposes of illustration. Continuing improvement and upgrading of product designs may have caused changes to your hammer which are not included in this publication. Whenever any question erises regarding your hammer, or this publication, please consult your HANWOO dealer. Safety The safety section list contains basic safety and operating precautions. Read and fully understand the basic precautions listed in the safety section before operating, or performing lubrication, maintenance, and repairs on, this product. Operation This section includes discussion of work preparations and operating techniques. ‘The operating techniques outlinad in this publication are basic. Skill and techniques develop as operators gain knowladge of the hammer and its capabilities. Maintenance Maintenance section is a guide to proper of the equipment. lilustrated, step-by-step instructions are grouped by service Interval. Items without specific service Intervals are listed. items in "Maintenance intervals” chart refer to detailed instructions below. Maintenance Intervals Use the service hour meter of main machine to determine servicing intervals. Periodical intervals shown (daily, weekly, monthly, ete.) may be used instead of service hour meter intervals, if they provide more convenient servicing schedules, and approximate to the indicated service hour meter reading. Recommended services should always be performed at the Intervals that occur first Under extremely severe operating conditions, more frequent lubrication than specified in the “Maintenance Interval’ instruction may be necessary. Performing service on items at multiples of the original requirement, for example, at “Every 50 Operating Hours or Weekly” and “Every 10 Operating Hours or Daily”.1. Safe operation 4s WARNING Injury or death can result from Improper operation or maintenance. 7 De not operate, or work on, this machine unless properly instructed. : Read and understand the operation and maintenance manual. Additional manuals are available from HANWOO hammer dealers. “© Before starting carrier, check all controls and warning devices for correct operation. =r Do not use hammer if hydraulic hoses vibrate excessively, Check hammer’ s hydraulic accumulator for damage and gas pressure. If needed, repair. = Stop operation as soon as the hammer object is broken. If operation continued, idle blows, could result in excessive wear of major components, or parts damage. = Do not use hammer to move rocks with end of chisel, > or with hammer body. - |= Do not use chisel as a lever. Hammer could be damaged through bolt, chisel, and/or front head, + Move impact point of object, if hammer object does not break in 30 seconds. = Do not use hammer in water. Corrosion of hammer, or non-lubrication, could result in further damage of the hydraulic components and front bush of the hammer. Should you contemplate hammer in water, contact with a Hanwoo Distributor. = Do not use hammer as a hammer. ‘The hammer is much heavier than the bucket And such usage could result in damage of the front head or swing mechanism of the main machine. « Do not operate hammer with boom or arm cylinders fully extended( bottomed out). ‘This may result in hammer shock, and damage to the cylinder or fronthead. Maintain 100mm cylinder stroke at least. bs]= Do not curl hammer chisel tip into arm or bosm when travelling or parking carrier. * Do not strike in one spot for more than 30 seconds at a time. If object dose not break, stop the hammer and change position of chisel, Working too long in one spot will create excessive 4 ~ 55 ¢ o stone dust under chisel. Dust dampens impact effect, and can be damage piston seal. = Never use hammer as a transporter. This could result in tipping carrier, or damaging carrier or the hammer. ~ Operate hammer only to the front and rear of the excavator. Do not use hammer at elther side of carri This may result in tipping excavator, or in damaging cartier swing device.2. Hammer Specifications 2.1, Specification of RHB301/302/303/305. ems unit| nip 301 | RHB 902 | RHB 303 | RHB 905] REMARKS Weight Without Bracket kg 65 70 100 155 With Chisel With Bracket xg | 75173 | 95/09 | 188/150 | 247/220| SIDE /TOP Length mm | 1012/1160] 1050/1180] 1088 / 1205|1966/ 157 SIDE/ TOP Pormitted | Flows wmin| 18~25 | 20~95 | 25~45 | as~ss Working Pressure | bar | 100~135] 100~135 | 100~135 | 120~t160 Bounds bpm | 670~1200] 600~1100|550~1050| 450~900 Rated "| Flows vin) 20 30 | 25/38 | 40 | wathLoad Working Pressure | bar | 125 128 [120/100] 120 Bounds bom | 920 eso |715/750| 560 Blowing Power u | 24s 298 avs | 1085, Chisel Dimensions mm | $48-L480 | ¢50-L490| $55-L500 | #68-L700| Die-Length Hose Dimensions PF 8 PF 12" PF W2"- PF V2" L1250-Pano | L1250.P280 |. 1250-P260 1900-280) engt-Prossure Back-Head ~ 7 10 | 13~ Race var} a~io | a~1o | 810 18| 20% ACC. Charging Pressure bar} - : 7 20% “Through Bolts 390~440| 890~440 | 440~490 | 780~a20] Tightening | acc.ivalves | Nem| : - : Torque Side Botts 290 / 390 | 290/890 | 290/390 | 780/980] tmner/ Outer rm | 0.01~0.03|0.03~0.05| 0.05~0.1 | 0.06~0.2| Bucket Volume | Applicable Excavators oe al bi af = ton| 0.7~15 | 08-3. | 2.0~4.0 | 2.5~6.0 [Machine Weight % bpm = Beats per Minute2.2. Specification of RHB313/322/328/332 UNIT] RHB 313 | RHB 322 RHB 392| REMARKS. Weight | Without Bracket | kg 842 870 ‘With Chisel kg | 780/750 | 1600/1480 2450/2800] SIDE / TOP Length mm | 1900/1960] 2366/2746 2813/3210| SIDE /TOP Permitted Umin | 80~140 | 130~200 170~250 Working Pressure | bar | 140~170] 160~180 bpm | 450~-800] 330~s50 Rated vmin| 95 150 With Load Working Pressure | bar | 155, 170 bpm} 525 380 Blowing Power a 2700 6100 Chisel Dimensions mm | $105-L1050 | ¥195-L1200 Dia-Length Hose Dimensions Pras". | ORFSH6-PFI Size- Li7s0-P2¢0 | L1250-P280 Length-Pressure| Back-Head fetae presents bar | 13~16 | 13~16 200 ACC. Charging Pressure bar - 20° ‘Through Bolts 1470~1870 | za50~2960 Tightening AGC. / Valves. | Nem : Torque 980/ 1180) 780/980 Inner / Cuter cease m | 0.4~0.65| 0.7~0.9 Bucket Volume| TON] 8~15 | 18~25 Machine Weight o® bpm = Beats per Minutereer roe 3. Structure 3.4. Power Cell | Valve Housing Valve Cap Back Hoad Valve Accumulator Chige! Bush Back-head Nut if Tough Btta crise j todee | Opin is ‘Bush Prossure-adust Front-haad Nut VaNe Froni-tead 1) Cylinder assembly @ This contains the moving piston, which strikes the chisel, The seals for both ends of the piston are also located in the cylinder. The seals for the upper ‘end of the piston are located in a removable cylinder bush, while the seals for the lower end of the piston are located in grooves machined directly into the eylindor. 2) Piston The piston transfers impact power to the chisel, generated by hydraulic power.3) Cylinder Bush The bush has oi! seals to seal back-head gas, and to prevent hydraulic oll leakage. 4) Valve Housing This guides the valve, which consists of inlet and outlet passages and chambers. 5) Valve Assembly (Our control valve is protected patent design. Assembled on the cylinder is the control valve, which controls oil flow through the hammer and, therefore, piston movement. Located directly above the control valve are the inlet and outlet hose adapters. Tho valve controls reciprocal piston action with hydraulic fluld distribution. ‘The valve assembly Is mounted on the cylinder assembly. The valve housing is marked with an “I” for pressure and an “O” for tank, to designate the locations, of the hose adapters, and runs for the lines to the hammer. 6) Valve Cap The vaive cap limits the stroke of the valve, and guides the valve. 7) Pressure Adjust valve The pressure adjust valve adjusts the hammer drain pressure during piston raising. By controlling the working pressure, the blow power can be increased or decreased. Turn the setting ecrew clockwise to increase working pressure, counterclockwise to decrease it, 8) Accumulator assembly ‘The accumulator Is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure, Accumulators are used in hydraulic circuits in a similar fashion as condensers ( or capacitors ) are used to collect, store and main electrical energy in electrical circuit, In a hydraulic circuit, minor variations or lags in pump output that might otherwise cause unsteady or irregular operation are made up from the supply of pressurized oil in the accumulator. Accumulators are solidly constructed to resist high fluid operating pressures. They have only three main moving part the compressible, precharged upper chamber; a vaive asgembly at the bottom of the accumulator, to allow the hydraulic fluid to pass in and out; and an elastic diaphragm, which ‘separates the two chambers, The flexible diaphragm changes shape to conform to changing upper and lower chamber Pressures and volumes. valve assembly at the top, to allow charging or discharging gas from9) Front Head assembly ‘This retains the chisel, using the chisel pins. By removing these pins, the chisel can be changed quickly. Four through bolts assembled into the front head hold the cylinder, a front-head and back-head assemblies together. 10) Front Bush and Chisel bush These guide the chisel, and the chisel bush limits the uppermost position of the chisel “They are consumable parts, which should be checked for wear limits. If needed, they should be replaced, 11) Chisel This transfers piston blow power to the objects. We recommend that various tool shapes according to working circumstance. 12) Chisel Pin This ‘stalled on the front-head, and stops the chisel from coming off. 413) Back Head assembly ‘This contains the cushion chamber charged with nitrogen gas that compresses during upward strokes of the piston; and serves to provide maximum absorption of piston recoll, efficiency storing this energy for the next blow. 414) Through Bolts These are used to assemble the fronthead, and the cylinder and the backhead. They have to be constantly tightened to specified torque. Inspect the bolts for loosening, and re-tighten thom weekly.4. Working Principles. 4.1. Working Principle for RHB322/328/332 models. 1) Set Up Chambers C3, C2 always maintain low Pressure, because they are connected to the tank, Chambers V3, Vi, C1 and accumulator always maintain high pressure, because they are connected to the working pump. Chamber V2 pressure is changed to low pressure or high pressure depending on piston position. 2) Piston Ascent Oil enters Into “IN” port, and begins to accumulate force to reise force is applied on A1 of piston lower flange, and piston begins to raise. When the piston begins to raise, oll from C4 chamber retums to the tank through the controt vaive, iston; hydraulic 3) Valve Ascent ‘When piston raises to around upper limits, 1 of piston lower flange reaches chamber G2, and the back-head Nitrogen gas is compressed, At this time, oll from chamber C2 goes to chamber V2. A@ area is larger than Ad area, but applied pressure of area AG is the same as applied pressure of Ad. Therefore, the valve begins to raise, because of the area difference between Ad and As. Valve Shitting ‘Chamber Back Head GasCustion ‘Chanter ce Front Hoad Chisel Fin Valve Ascent 10 -4) Piston Descent When the valve reaches the upper limits, chamber C4 becomes high pressure area, because oll from the working pump goes to chamber C2 through the control valve holes. A2 area is larger than At area, but pressure applied to A4 area is the same as the pressure applied to At. Therefore, the piston begins to descend, because of the area difference between Az and At. At this time, piston descent speed is aceslerated by compressed nitrogen gas pressure and piston weight. 5) Impact Chamber V2 is changed in low pressure ‘as chamber C2 is connected with G3 during piston descent. But V3 is always high pressure. ‘Therefore, the vaive begins to descend. 6) Continuous Strike After the piston strikos the top of the chisel, the status of all circuits are changed to “Piston Raising” ‘The piston begins to raise via status flowing into “IN” port, and the cycle is ropeated again. Piston Descent Impact4.2. Working Principle for RHB301/302/303/305/308/313 4) Set Up Chambers C3 and G2 always maintain low pressure, because they are connected to the tank. ‘Chambers V1, C1 always maintain high Pressure, because they are connected to the working pump, Areas AS and A4 always maintain high Pressure; but AS area and chamber V2 Pressure is changed to low pressure or high pressure depending on piston position 2) Piston Ascent Oil enters into “IN” port, hydraulic force is applied on At of piston lower flange, and the piston begins to raise, As the piston begins to raise, oil from C4 chamber returns to the tank through the control valve, 3) Valve Ascent When piston raises up to around upper limits, A1 of piston lower flange reaches chamber G2, and the back-head Nitrogen gas is compressed. At this time, oll from chamber C2 goes to chamber V2. Area of both AS and AS is larger than area of A4; but the pressure applied to area A3 and AS is the same with that applied to Ad. Therefore, the valve begins to raise, because of this area difference. Back Head ca Sf fa] L. Piston vw pt aoe ce] — Lpte | ce finder one - ei Piston Ascent Valve Ascent -12-4) Piston Descent When the valve reaches the upper limits, chamber C4 becomes a high pressure area, because oil from the working pump goes to chamber G2 through the contro! valve holes. Area A2 is larger than area At, but pressure applied to area Ad is the same ‘as the pressure applied to At. ‘Therefore, the piston begins to descend, because of the area difference between Ag and At, At this time, the descent speed of the piston is accelerated by compressed nitrogen gas pressure and the weight of the piston, 5) Impact Chamber V2 Is changed to low pressure as it connects chamber C2 with C3 during the piston descent, But V3 is always high pressure. Therefore, the valve begins to descend. 6) Continuous Strike After the piston strikes the top of the chisel, the status of all circuits are changed to “Piston Ascent” The piston begins to raise by the pressure flow Into “IN” port, and the cycle is repeated. 1 Le oon Leth by] io we L ox —p lLoee=o| fa Piston Descente . [ i omy By eo L i | ca (os eee 13 - Impact5. Pipe lines 4 IMPORTANT Check the pipe lines for correctness of such as pressure, flows or pressure loss, if the carrier has hammer pipe lines. A secondary relief valve has to be installed if there is no secondary vaive onthe control valve. Specifications for pipe lines. Mode! | Pipe Dimensions Hose Dimensions Remarks RHB301 | 9/8” Hose( P2680) PF8/8” .1250-P280 RHB302 | 4/2” Hose( P280) PF1/2” L1250-P280 = Look at bucket in operator room FHB303 | 1/2" (Schedulego ) PF1/2” L1250-P260 RHB05 | 1/2” (Scheduleso ) PFI/2" L1300-P280 High Pressure : Left-hand side RHB313 | 9/4” (Schedules ) PF9/4" L1750-P280 Low Pressure : Right-hand Side| RHB322 | 1” (Scheduieso) | ORFS#16-PF1” L2200-P350 RHB328 | 1” (Scheduleso) | ORFS#16-PF1” L2200-P350 RHB332 | 14” ( Scheduleso ) [ORFS#16-PF14” L2400-P350|6. Hammer Installation & Removal 4 WARNING When aligning linkages, never insert fingers into pin holes. Unexpected machine movement may occur in this situation and cause a severe injury. Match holes by visually lining up. Use sharp-tipped, soft pencil point of similar to check for high spots or irregularities, While ining arm holes, or moving bucket, make sure that there are no person in the of the arm or bucket. 6.1. Hammer Installation. Ay WARNING Personal injury can result from dropping pins during installation. ‘Wear safety shoes to protect feet. 1) Set hammer on clear, flat, level ground. 2) Remove bucket, referring to Carrier Operator’ s Manual. 3) Insert cartier arm pin and assemble fasteners. 4) Set engine speed to at low idle, and slowly move arm, and align the arm holes with the mounting holes. - 65) Move bucket cylinder, align the bucket linkage holes with the mounting holes. Assemble fastenors. 8) Remove end caps from the stop valves, and remove Plugs from hoses, and connect the hoses to stop valves at both sides of the arm. 7) Turn stop valves to “ON” position, - 16 -6.2. Hammer Removal 4 WARNING Wear safaty shoes to protact feet. Personal injury can result from dropping pins during removal. 1) Set hammer on clean, flat, level ground. Engage parking brake 2) Tum stop valves to “OFF” position 8) Disconnect hydraulic hoses from stop valves. Ensure no leakage occurs from hoses and stop valves, 4) Apply end caps and plugs to hose ends and fittings to prevent contamin: 5) Remove pin fixing fasteners. 6) Remove pins, 7) When pins have been withdrawn, move operating joystick slightly, to take weight off remaining link pins. 8) Lift arm away from hammer, so that hammer can be carrled away, or another attachment mounted on cartier. -W-7. Chisel Installation & Removal 7.1. Chisel installation 7.1.1, Chisel installation for RHB301/302/303/305 models. A. WARNING Personal injury can result from dropping chisel during installation. Wear safety shoes to protect feet. A WARNING When charging backhead gas pressure, chisel may jump out. Do not stand in front of chisel, to aveld accidents. 4. WARNING When releasing gas pressure, avert eyes away from gas valve. Debris can result in serious to the eyes. 1) Set hammer on level ground. 2) Make sure that Carrier’ s transmission is in neutral, and parking brake engaged. 3) Stop engine, / 4) Release backhead gas pressure. 4 Refer to "Nitrogen(N2) Gas Charging and Release” (see pages 29~31 for details.) 8) Draw out locking pin@) with small driver and round bar provided by Hanwoo, toward lower side as far as locking pin®, which you wil reinstall. 6) Remove holding pind, 7) Install chisel®, aligning it’s cavity with hole, for easy fiting of chisel pin@. 8) Install chisel pin®. 9) Install holding pind) 10) Draw in locking pin@ with hammer and round bar, toward upper side. 11) Charge backhead gas prossure, Refer to “SPECIFICATIONS (seo pages 5~6 for details)"7.1.2. Chisel \stallation for RHB313/322/328/332 models. 4 WARNING Personal injury can result from dropping chisel during installation. Wear safety shoes to protect feet. Ay WARNING ‘When charging backhead gas pressure, chisel may jump out. ‘Do not stand in front of chisel, to aveid accidents. Ad WARNING When releasing gas pressure, avert eyes away from gas valve. Debris can result in serious to the eyes. 4) Set hammer on level ground. 2) Make sure that carrier’ s transmission is in neutral, and parking brake engaged. 3) Stop engine. 4 4) Release the backhead gas pressure. Reefer to “Nitrogen(N2) Gas Charging and Release” (see pages 29~31 for details.) 5) Push holding pin) as far as it will go. 6) Remove locking pin@ towards left side, pushing It through hole. So 7) Install chisel@, aligning it’ s cavity with hole, for easy fitting of chisel pins@ later. 8) Install two chisel pins®. 8) Push holding pind). Insert locking pin@ to right side, pushing it through hele. 10) Charge backhead gas pressure. Refer to “SPECIFICATIONS (see pages 5~6 for detais.)" -19-7.2. Chisel Removal 7.2.1. Chisel removal for RHB301/302/303/305 models. Ay WARNING jury can result from dropping chisel during installation, Wear safety shoes to protect feet. A WARNING When charging backhead gas pressure, chisel may jump out Do not stand in front of chisel, to avoid accidents, 4 WARNING ‘When releasing gas pressure, avert eyes away from gas valve. Debris can result in serious to the eyes. 1) Set hammer on lovel ground, 7 2) Make sure that cartier’ s transmission in neutral, and parking brake engaged, i 8) Stop engine, i 4 4) Release backhead gas pressure. Refer to “Nitrogen(N2) Gas Charging and Release" (see pages 29~31 for details.) 5) Oraw out locking pin@ with small driver and round bar provided fram Hanwoo, towards lower side as far as locking pin®, which you will reinstall 6) Remove holding pin. 7) Remove locking pin@ to left side, pushing It through hole, . 8) Remove chisol pin@. 9) Remove chisela).7.2.2. Chisel removal for RHB313/322/328/332 models. 4 WARNING Personal injury can result from dropping chisel during installation. Wear safety shoos to protect feet. 2. WARNING When charging backhead gas pressure, chisel may Jump out. Do not stand in front of chisel, to avoid accidents. Ay WARNING When releasing gas pressure, avert eyes away from gas valve. Debris can result in serious to the eyes. 1) Set hammer on level ground. 2) Make sure that carrier’ s transmis and parking brake engaged. aru lk 4) Release backhead gas pressure. Refer to "Nitrogen(N2) Gas Charging and Release” (see pages 29~31 for details.) §) Push holding pin) as far as it will go. 6) Remove locking pin@ to the left side, pushing It e through hoie. EQ 7) Remove two chisel pins®. ZS 8) Remove chisel®.8. Pre-operation, Checks. 8.1. Checking stop valves ‘Check stop valves, Stop valves must be open before operation. 8.2. Checking nitrogen(N2) gas ‘Check nitrogen(N2) gas before operation. If needed, recharge or discharge nitrogen(N2) gas. See pages 29~31[8.2. Nitrogen(N2) gas pressure charging] for details. 4A. WARNING Use only Nitrogen(N2) gas for charging accumulator and backhead. Never use oxygen or shop air, 8.3. Checking hydraulic oil 8.3.1, Recommended hydraulic oils Normatly any hydraulic oit originally intended for carriers can be used in Hanwoo hammer. However, since working with hydraulic hammers will heat the oll much more than in normal excavation works, oil viscosity must therefore be checked. When hammers are used continuously, the oll temperature normalizes at certain levels, depending on conditions and carrior, At such temperatures, hydraulic oil viscosity should be 20-40 eST. Some recommended oll types from major oll manutacturers. ae Lubricant Hydraulic ol! Manufacturer Total Total Equivis 2846 Shell Tellus 32 Mobil Mobil DTE13M (All Temp) or DTE24 (Summer) Yukong ‘Supervis HV146 N46 and ZIC Supervis X40 Caltex Caltex HDs2, -22-‘Ad CAUTION Never mix olls from differant manufactures. Hanwoo does not endorse specific brands but does suggest that operators select quality oils whose suppliers provide assurance that required standards will always be met or exceeded. 8.3.2. Hydraulic Oil Changing intervals Contamination of hydraulic oll may result in parts damage, not only in hammer, but also in cartier main components. We recommend hydraulle oil and oil filters replacement as shown in the following table, which is based on 100% hammer operation. Hydraulic oi! Every 600 hours Based on 100% hammer operation ers Every 100 hours 8.3.3. Hydraulic Oil Hammer must not be started if hydraulic oll viscosity exceeds 1000 cST, nor operated when hydraulic oll viscosity falls 15 oST. Oil viscosity too high + Start up difficulty - Operation stiffness + Inegular hammer striking - Danger of cavitation in pumps and hydraulic hammer - Valve sticking - If fitter is very contaminated - Hydraulic components could be damaged, due to open bypass valve Oll viscosity too low - Efficiency losses from internal leakage - Damage to seals, O-rings - Accelerated wearing of parts, because of decreased lubrication efficiency. - 23 -8.4, Checking grease 4 CAUTION Insufficient greasing may cause abnormal wear of chisel bush and chisel, and chisel breakage 4 IMPORTANT Do not use lubricants other than those recommended, without prior written approval from Hanwoo. © Apply grease to chisel bush and chisel every two hours ee) ‘© Adapt grease interval and amounts to chisel wear rates and working conditions. © Chisel shank must be well lubricated before installing chisel Greasing ‘© While greasing, hammer must be upright against the chisel, to ensure that grease will penetrate between chisel and bush. Recommended Lubricant Greases Lubricant Grease Manufacture? Total Total EP#2 Shell Alvania EP#2 Mobil ‘Mobil FAWH2 Or Cold Temp Mobi FAW #1 Yukong Crown EP2 Caltex Muliipac EP2 - m=8.5 Bolt and nut Torque specifications. SPEC HEAD SIZE TORQUE REMARKS: Kot-m | Nem Pri _| S Hex Socket 3n4 30~40 Pri | 8 Hex Socket aio | 80~100 PT Aa 6 Hex Socket 4-6 40~60 | Grease Nipple PT 12 | 10 Hex Socket qa—1a | 120-135 - | Prim | 14HoxHead 3x6 30~60 PF WA 6 Hox Socket 2~25 20~25 PE i | 12 Hex Socket 46 40~60 PF 1/2 _ | 10 Hex Socket 1o~12 | 100~118, PF am | 12 Hex Socket 20~25 | _195~245 PF 12 27 Hex Head 20~25 | 195~245 [Pri | S0HexHead 20~25 | _ 195~245 : Praeprae | _22 Hex Head 13~20 | 150195 prieprin | e7HexHead | 20~25 | 195~245 Praapraa | 30 Hex Head g0~35 | 295~345 “| Tiet@UNPFi| 44 Hox Head 50~85 | _490~540 Fee | away] 6oHexHead | S085 | as0~640 | Mi6x 16 | @ Hex Socket 4~6 40~60 20x15 | 17Hex Socket | _S0~88 | _490~S40_| RHBaZ2/S28/052 Acc. Bolt M22.x1.5 | 10 Hox Sooket 10 | _80~100 | Aco. Charging Plug Mi0x1.0 | 19 Hex Head 3~4 30~40 | Gas Vaive Plug HEHE | wiexi.6 | 24 Hex Head ts~18 | _150~175 | Aco, Charging Cap “M20x1.5 | 92 Hex Head 20~25 | _195~245 | Gas Valve [m20x2.5 | 90 Hex Head 30/40 "298/390 _ | RHS301/002/006 Side Bol (INNER/OUTER) Wa0x2 | 46Hex Head B0100 780/680 _| RHES0S Side Bot (NNEROUTER) iwaox5 | SBHoxHead | 100/20 | _980/1180_| RHBA1S Side Bot ((NNER/OUTER) M30 x85 | 46 Hox Head ‘BO/100 7e0/980 | RHBS22 Side Bott (INNER/OUTER) Maéx4 | S8Hexread | 100/120 | 980/1160 | RHBa2a/a%2 Side Bott (NNER/OUTER) Ma0xss | 41HexHead | 60~1007 | _80~980_| Cushion Plate Bolt 20x25 | S0HexHeed 30/40 295/300 | AHESIG Top BAT. Bal (NNEROUTER) Mg0x2 | 46 Hex Head ‘80/100 "780/580 _| AHEG22/G28G%2 Top BKT. Bok (INNERIOUTER) Mz0x26 | s0HexHead | _40~45 | _390~440 | AHB901/G02 Through Bott me2x2.6 | SéHexHoad | 4550 | _440~490 |RHEGOS Through Bolt M27x3 | ai Hextoad | 60~85 | _760~890 | RHSG0S Through Bort Maexa | S8Hextlead | 150~160 | 1470~1570 | RHBS1S Through Bolt ‘oda x16] 68 Hextlead | 240~260 | 2350~2450 | RHB322 Through Bolt ADsx1/5| 78 HoxHead | a00~210 | 2940~s040 | AHBAZE Through Bolt | nosax16 | 7eHoxtead | 380~360 | 3430~3590 | AHB332 Through Bolt = 25 -8.6. Operating temperatures The hydraulic oll operating temperature is -20°0- +80% (-4°F - +176°F), If the temperature is lower than -20% (-4" the hammer and chisel have to be preheated befora starting operation, in order to avoid breakage of the accumulator membrane and chisel To preheat hydraulic oll, operate carrier (without running hammer), until oll temperature "98 specified temperature range. During operation, om wi! remain warm. IT hydraulic oil temperature exceeds specified limits, please stop equipment and don’ t restart eperation until oil has cooled to specified operating temperature range. 8.7. Cooling Maximum permitted hydraulic oll temperature range in continuous hammer use is 50-800 (120-175°F), depending on viscosity of oll in the system. Therefore, a reliable hydraulic oil thermometer is necessary. If there is no thermometer on the cartier, one must be installed. Hyciraulic oll temperature depends on ambient conditions, cartier cooling system efficiency, and on hammer use. When hydraulic hammer Is used continuously, it is necessary to have a cooling system with ‘extra cooling capacity, as compared with normal excavation work, ~ 26 - eS9. Maintenance Grease pot Check hyd cl for leakage (Check N2 Gas for leakage Through batt %#Serlal No. Reading method AB—CDE—FGH MANUFACTURING SERIAL No. EX) 001, 002, 003, 004, 005, MODEL NAME, EX) RHBS01;301, RHB302;302--- YEAR of MANUFACTURE EX) 1997;97, 1998;98, 1999;99,, - 27 -At the following work intervals, specified points should be inspected precisely. 9.1 Maintenance Intervals. 9.1.4, Every 2 hours ~ Grease gap between tool and front bush ~ Check hydiraulic oil tomperature, piping and hose connections, and working condition. ~ Check tightness of fasteners 9.1.2, Every 10 Hours, or Daily ~ Chisel and pins - remove rough skin if found. ~ Check tool greasing, and shorten greasing interval, if required. ~ Check gas pressure of accumulator and back head, 9.1.3. Every 50 Hours, or Weekly - Check chisel and front bush wear. ~ Check hydraulic hoses - replace, if needed. = Through bolts - re-tighten If needed 9.1.4. Every 100 hours, or 6 Months ~ Factory inspection by authorized service personnel recommended. + All hydraulic pipe and hose connections. - Hose intereference from carrier movement. - Conditions of oil filter, accumulator diaphragm, and through bolts. 9.1.5. Every 600 hour, or annually - All hydraulic pipe and hose connections. - Hose intereference with excavator boom. = Conditions of oil fliter, accumulator diaphragm, and through bolts. + All Seals + Conditions of piston and bush. - 28 -9.2. Nitrogen(N2) gas charging and release. Charging kit(p/n:K091-0028) is provided by Hanwoo as standard Spare part. 9.2.1. Backhead Gas Pressure Release x WARNING When releasing gas pressure, avert eyes away from gas valve. Debris can result in serious injury to the eyes. 4) Remove plug® from gas valve@) on backhead@. ‘ 2) Press down the check valve through the gas \ | charging valve hole, using clean metal stick roa. t toa — a 8) Keep held down until no sound coming emanates moet : from valve. 7 -29-9.2.2. Backhead Gas Pressure Charging, 4. WARNING When charging backhead gas pressure, chisel may jump out. Do not stand in front of the chisel, to avoid accidents. Backhead Temperature were) 40 | 0 | 10 | 20 | a0 | 40 Modet RHB301/902/503 s {93 [96 | 10 [102 | 408 ANBsos/s1s/s22/828 [13.6 | 14 [1451 16 | 156 | q6 RHBS32 179 | 186/198 | 20 | 207 | e14 1) Remove cap nut (or bolt}® from gas charging valve on backheadD. 2) Set gas pressure charging kit(p/n:K091-0026) as shown in above figure. 98) Connect kit threaded pon@ to back head gas charging vaive. 4) Open vaive® slowly, keeping bution pressed down, and read gauge indicator®). 5) Compare read values with specifications. If measured gas pressure differences exceed accordingly specified pressures by -+ 10% , or more, discharge, using vent vaive®, or charge nitrogen gas. 6) Disconnect fittings. 7) Re-install cap nut (or bol}, 8) Check O-ring for damage. 9) Apply soap solution on valve, and check for gas leakage. -- 30 -9.2.3 Accumulator Gas Inspection and Charging. 4 WARNING Personal injury or death can result if accumulator gas is charged incorrectly. Proper inspection, charging equipment, and training in equipment operation are necessary, explosion. Ay DANGER Personal injury or death can result if people stands in front of chisel during accumulator Ay CAUTION ‘Never use oxygen or shop air for charging. Release all prassure prior to servicing or disassembly. Study all service and operating instructions before using hammer. Do not overcharge gas pressure. Do not weld or modify the accumulator in any way. 1) Remove charging plug® of gas charging port, and loosen valve cap@ of accumulator charging valve and valve. 2) Screw in adapter® of nitrogen gas charging kit(p/n: KO91-0025) securely to the charging adapter®. 3) Open valved) slowly, keeping button® pressed down and read gauge indicator®). 4) Read gas pressure, and compare with specification, shown on above graph. If measured gas pressure differences exceed specified pressures by( 60 Bar) ++ 10% or more, discharge, or charge, nitrogen gas accordingly. 5) Take hand away from button and securely close valve). 6) Remove inspection kit, and securely close plug@. 7) Tighten valve® and valve cap@. 8) Open discharge valve@ of charging kit to vent gas. 9) Apply soap solution to valve and plug, and check for gas leakage. -31-9.3. Through Bolt Inspection and Replacement Ay CAUTION Release completely backhead gas pressure prior to loosening through bolts. Backhead ejection when removing through bolts can results in a severe injury. 1) Discharge nitrogen gas of backhead completely prior to loosen through bolts. 2) Remove ail through bolts, and inspect for presence of any cracks on through bolts. 3) When installing through bolts, tighten bolts one turn at a time in diagonal sequence; not each nut completely all at once turn of times, not completely at once. 4) Use torque wronch of specified range. Refer to “SPECIFICATIONS (see pages 5~6)" ~ 32 -9.4, Seal Inspection and Replacement 41) if any hydraulic ol leakage from hammer is discovered, faulty seals should be replaced. ‘To figure where seals are bad, refer to following drawings; Backup ring- worn, O-ring & dust seal Packing - deformed, worn, jorated distorted, perished distorted worn, det 2) When a bad seal is found, the cause of the damage must be determined and rectified. 2) When a step seal is changed, apply grease to seal and seal seat, and hold seal firmly with idle fingers, as per marking. Be careful net te break seal through excessive deformation. - 33 -9.5. Chisel and Front Bush Wear Inspection. FRONT BUSH \ WEAR CHISEL clearance between chisel and chisel bush is too big, this could cause of damage, or breakage of chisel through piston irregular contact. If chisel wear exceeds 2mm, or chisel bush wear exceeds 4mm, replace. The following table, Is an Illustration of standard chisel and chisel bush dimensions, for reference purposes. Chisel and Chisel bush standard dimensions. RNB01 | RHB902 | RHBGOS | RHBS05| AHBSt9 | AHESz2 |pHES28 | AHBGGD Fis Chisel | 45 | sso | sss | ges | #105 | s1a5 | v1s0 | 4152, us si6i crush | eae | gor | sr | goo | ior | gta | vie | 41st, 34 -10. Trouble shooting ‘Symptom Cause Required action Low impact power 4, Hydraulic oil contamination, or heat deterioration 5. Poor main pump performance 6. Back head nitrogen gas low Low flow rate by mis-adjustment of flow control pressure reduction valve 8. Chisel out of range for blowing position 1. Excessive back head gas pressure | 1. Re-adjust nitrogen gas pressure 2. Stop valve(s) closed 2. Open stop valve 3. Lack of hydraulic oil 3, Fill hydraulic oil Nobiow out | 4. Wrong adjustment of pressure] 4. Re-adjustment valve reducing valve 6. Tighten or replace 5. Faulty hydraulic hose connection | 6. Replace back head O-ring, or 6. Oil in back head Infection cylinder bush step seal 1. Line leakage or blockage 1. Check tines 2, Clogged tank retumn line fiter 2. Wash filter, or replace 3, Lack of hydraulic ol 8. Fill hydrauite oll 4. Replace hydraulic oil, rinse tank and replace hydraulic oil inside lines 6. Call authorized service man 6. Refill nitrogen gas 7. Re-adjust reduction valve 8. Push down chisel by excavator operation, Irregular impact 1, Low accumulator gas pressure, or bad accumulator 2. Bad piston or valve 3, Piston moves down/ up to blank blow hammer chamber. 19 surface, 1. Refill 2. Call authorized service man 3. Push down chisel by excavator operation rogen gas Bad chisel movement 41, Chisel diameter incorrect Chisel and pin Jammed from chisel pin wear 3. Jammed front bush and chisel 4. Deformad chisol and piston contact 1.Replace chisel with genuine replacement parts 2, Smoothen rough surface of chisel 8. Smoothen rough surface of front bush interior 4. Replace chisel ‘Sudden reduction power and pressure linevibration 1, Accumulator gas leakage Accumulator diaphragm damage 1. Replace O-ring, or refill nitrogen gas 2, Replace diaphragm 1. Cylinder seal worn, 1, Replace seal Gas leakage 1. Oring damags rolated parts 1, Replace relevant O-ring - 35 -11. Chisel Claim Judgement Criteria Fhinoceros chisels are manutactured through a process of strict manufacturing and quality control, from receipt of materials through processing, heat treatment to post-treatment, Chisel materials are $0 stored and managed as to onablo quality record tracing throughout normal chisel life span, right from delivery. However, apart from chisel quality, chisel operating life may vary signifieantly according to operating conditions and methodology, or according to type of ‘m sterial worked on, making it dificult to guarantee a standard operating fife. Hence, to help users use our products correctly, and ensure long operating life, these claim judgement criteria present defect examples that can occur during use, and the disposition standards applicable in each case. 11.1. Breakage of piston striking point or of chisel pin contact corners. (Figures 1 and 2) Breakage of piston striking point or of chise! pin contact comers is extremely rare. This phenomencn occurs when material quality is non-uniform; heat-treated material is very brittle: or striking force is being concentrated on the chisel comers due to unsatisfactory flatness of piston and chisel striking point, If such defect occurs, affected chisels may be replaced free of charge.

~ 36 -11.2. 11.3. Plastic deformation of piston striking point (Figure 3 ) Rhinoceros chisels are manufactured only from top-quality materials, and are appropriately heat-treated to effectively withstand the stresses applied to each product element. Hence, the possibility of chisel tip plastic deformation occurring due to piston hammer is extremely stim. Such defects may occur due to material strength deficiency, or brittleness, resulting from unsatisfactory heat-treatment. If such defect occurs, affected products may be replaced free of charge.

Breakage inside basic line (Figures 4 and 5) ‘Should product breakage occur in any direction at a point i in

, from the basic fine shown in < Figure 4 >, this may be dus to defective material, defective heat-treatment; chisel deformation, or unsatisfactory shaping of chisel heck. Should such defect occur, affected products may be replaced free of charge. de the front bushing, as shown In addition to the causes described above, product breakage inside the basic line may also ‘occur if the interval between the front bushing and chisel widens due to excessive wear of front bushing, coupled with excessive bending load being applied to hammer. If any trace of seizure, caused by friction between the front bushing and chisel, Is observed on the surface of the chisel body, and if it is clear that product breakage Is centered around the area of such selzure, affected products will net be replaced free of charge. -37-Batle Lice gS ge eee HELE ECE Ly 7) aya Z : SS ® Figure 4>

11.4. Breakage outside basic line (Figures 6, 7 and 8) ‘Should product breakage occur at a point outside the front bushing, as shown in

, this may be due to excessive bending load being appiled to the chisel. Such bending load occurs when, alter chisel has been inserted into ‘material, the chisel is pulled or pushed, or when the chisel is struck and pushed when it is not Porfectly perpendicular to the surface of the material being worked on. Fractures, in general, are of the form shown in

, Fatigue breakage, of clamshell form, develops in the areas near breakage start points, caused by stress concentration resulting from bending foads, and then quickly radiates outward. Such type of breakage may also occur due to Scarring of the chisel body during use. As breakages occurring outside the basic line are caused by improper working habite, as explained above, products incurring stich defects shall not be replaced free of charge. However, if a fatigue fracture start point occurs within the chisel body, instead of on the surface of chisel as shown in

, affected products will be replaced free of charge, as such breakage indicates matorial defect - 38 -11.5. Crushing of chisel tip (Figure 9) Rhinoceros chisels are heat-treated to exhibit high breakage- and wear-resistance; and detects such as crushing of the chisel tip

are not to be expected under notmal operating conditions. However, if a chisel is hammered continuously for a long period of time without crushing or puncturing the material being worked on, the temperature of the tip rises extremely high, inducing annealing of the heat-treated material, and bringing on plastic deformation (crushing), rather than wear. As explained above, crushing of the chisel tip is caused by Improper working methods, and, therefore, affected products will not be roplaced free of charge.

11,6. Chisel tip wear (Figure 10) Tho rates and types of chisel tip wear vary with work material and work method. If the diameter of the worn tip of a flat chisel is less than 2/9 of the chisel body diameter, as shown in

; and if the tip of a new pointed chisel is worn down in excess of 50mm lengthwise from the tip, this is considered normal chisel wear. Hence, chisels exhibiting such normal wear, as shown in

, will net be replaced free of charge. 50mm 40 Flat Chisel Pointed Chise!

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