Hammer V20GS
Hammer V20GS
Hammer V20GS
Vulcan V20GS
Operation
&
Maintenance Manual
CONTENTS
1. Specifications
1.1
1.2
1.3
2. Operation
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
Product numbers
Tool Selection
Breaking Principles
Correct working methods
Operating temperature
Other important points
Storage
Mounting and Dismounting the Hammer
Operating Pressure Settings
Hose and Pipe Specification
Hydraulic Circuit
3. Lubrication
3.1
3.2
Manual Lubrication
Hydraulic Oil
4. Maintenance
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Delivery Precautions
Inspection of the nitrogen gas charging in the back head
Inspection of nitrogen gas in the accumulator
Side Rod Inspection and Replacement
Adjusting Control Methods
Regulating oil flow rate of valve adjuster
Wearing parts
Wear limit of tool and tool bushing
CONTENTS
5. Disassembling and Assembling
5.1
5.2
5.3
5.4
Disassembling
Assembling
Torques
Workshop tool list
6. Troubleshooting Guide
6.1
6.2
6.3
Oil leakage
Irregular blows after normal beginning
No Impact
General
Safety
8. Parts List
8.1
8.2
8.3
Housing
Hammer Assembly (Standard)
Hammer Assembly (Auto-Grease)
Specifications
9.1.1 Models
9.1.2 Diagrams
9.1.3 General Specifications
9.2 Operation
9.2.1 Grease Filling Procedure Option 1
9.2.2 Grease Filling Procedure Option 2
9.2.3 Reinstallation and Operation of Grease Pump
9.3 Features
9.3.1 Benefits
9.3.2 Comparison to Manual Greasing
9.4 Installation
9.4.1 Model: HL11CU
9.4.2 Model: HL11CD
1. Specifications
1.1
Item
Specifications
Working weight
Impact rate
Operating pressure
Relief pressure
Oil flow
Back pressure
Tool diameter
Oil temperature
Hydraulic oil viscosity
Pressure line size
Return line size
Air (Under water)
Accumulator pressure
Backhead pressure
Carrier weight
1.1
Name
Length
mm (in)
Weight
kg (lbs)
Diameter
mm (in)
Cone tool
(A)
1200 (47.24)
116 (255.2)
135 (5.31)
Chisel tool
(B)
1200 (47.24)
116 (255.2)
135 (5.31)
Blunt tool
(C)
1200 (47.24)
118 (259.6)
135 (5.31)
Moil tool
(D)
1200 (47.24)
115 (253.5)
135 (5.31)
Notes
1.2
Structure
1) SIDE ROD
The front head, cylinder and the back head of the breaker body are secured with four side rods.
2) BACK HEAD
The gas charging valve is built in and charged with N2 gas to improve the hammering power.
3) CONTROL VALVE
The control valve is bolted onto the cylinder and it controls the pistons hammering action.
4) CYLINDER
The cylinder is the heart of the breaker body.
5) PISTON
The kinetic energy of the piston is converted into hammering energy when the piston hits the tool; this
consequently breaks the material.
6) FRONT HEAD
The front head supports the entire breaker with the thrust ring and the built in upper bushing protects the
carrier from the shock transmitted by the tool.
7) TOOL
The cone, chisel, blunt and moil tools are used for breaking different types of material.
2. Operation
2.1
Product numbers
2.2
Tool Selection
2.3
Breaking Principles
1) Blunt
For igneous (e.g. granite) and tough
metamorphic rock (e.g. gneiss) into which
the tool does not penetrate.
Concrete.
Boulders.
2) Impact breaking
In impact breaking, the material is broken by
transferring very strong mechanical stress
from the tool into the material.
The best possible energy transfer between the
tool and the object is achieved with a blunt
tool.
Impact breaking is most effective in hard,
brittle and very abrasive materials
2.4
2.5
Operating Temperature
2.6
2.7
Storage
Long term storage
Observe the following points when the hammer is stored for a long period of time. This will protect the
vital parts of the attachment from rusting, and keeps the breaker ready for use whenever it is needed.
1.
2.
3.
4.
10
2.8
Installation
1. Install the hammer in the same manner as mounting a bucket, install bucket pins.
2. Connect the hoses. Hammer inlet port is marked on the back head with IN and the outlet port is
marked with OUT.
3. Open the hammer inlet and outlet lines.
11
2.9
Model
V20G
Operating Pressure
160 ~ 180 bar
Model
V20G
1) Operating Pressure
Relief Pressure
200 ~ 210 bar
2) Relief Valve
12
Model
V20G
Hose Assembly
IN
OUT
PF 1
PF 1
13
Notes
3. Lubrication
3.1
Manual Lubrication
* Grease interval
1. The tool shank and tool bushing must be well lubricated before installing the tool.
2. Apply 40 50 strokes from the grease gun to the tool bushing and the tool at regular intervals.
3. Adapt the interval and amount of grease to minimize tool wear and keep it in good working condition.
Greasing should be done every hour.
Technical data:
- NLGI grade 2.
- Synthetic oil base with aluminum complex soap.
- Approximately 15% graphite copper solids to reduce metal to metal contact damage.
- Dropping point 260C (500F).
- Viscosity 15 cSt.
- Temperature range -30 ~ 230C (-20F ~ 450F).
14
3.2
Hydraulic Oil
2) When the too oil is thin, the following
problems may occur.
a. Efficiency losses (internal leaks).
b. Damage to gaskets and seal leaks.
c. Accelerated wearing of parts, caused
by decreased lubrication efficiency.
3) Special oils
In some cases special oils (e.g. biological
oils and non-inflammable oil) can be used.
Please observe following aspects when
considering the use of special oil:
The viscosity range in the special oil must
be within the range of 15 ~ 1000cSt
(2.35~131E).
15
16
4. Maintenance
4.1
Delivery Precautions
When a Vulcan hydraulic breaker is shipped
from the factory, the back head is not charged
with Nitrogen gas.
If the back head were charged with Nitrogen
gas, the front head of the piston is left protruding
from the cylinder.
4.2
WARNING!
1) Remove the gas plug on the back head.
Make sure you keep the o-ring in the plug.
2) Connect the charging block to the gas
charging valve on the back head.
3) Connect the N2 cylinder to the charging
block hose.
4) Ensure that the adjustment valve on the
charging block is closed.
5) Charge the pressure of the back head to
specifications by turning the handle on the
N2 cylinder counter-clockwise to open.
Increase the pressure shown on the
charging block by opening and closing the
N2 cylinder, close the cylinder when the
desired pressure is shown. Check the
charged pressure in the back head by
pressing the push rod on the charging
block.
6) Wait 2 minutes for pressure to stabilize
after closing the N2 cylinder.
7) Recheck the charged pressure in the back
head by pressing the push rod on the
charging block.
17
4.3
WARNING!
Never use anything but Nitrogen gas to charge
the accumulator.
1) Inspecting the charging pressure.
a. Install the adapter and the pressure
gauge on the charging block.
b. Turn the handle of the charging block
counter-clockwise.
c. Remove the plug on the accumulator and
install the charging block.
d. Turn the needle valve (2)
counter-clockwise slowly, and observe
the charging pressure on the pressure
gauge.
e. Ensure the charging pressure is correct
and tighten the needle valve (2)
completely.
f. Loosen Screw 1 to discharge the N2 gas
from the charging block.
g. Remove the charging block and tighten
the plug and the cap. Ensure that the
o-rings are installed in the plug and cap.
2) Charging the accumulator with N2 gas.
a. After performing the inspection of the
charging pressure, remove the cap of the
charging block.
b. Connect the gas hose to the charging
block and the N2 cylinder.
c. Turn the handle of the charging block
clockwise.
d. Slowly turn the handle of the N2 cylinder
counter-clockwise to charge the
accumulator with Nitrogen gas.
e. Tighten the needle valve (2) completely.
18
4.4
CAUTION!
Release the back head pressure completely before loosening the side rods. Not releasing the pressure in
the back head before removing the side rods can cause damage to the unit and serious bodily harm.
1) Discharge the N2 in the back head completely before loosening the side rods.
2) Remove all of the side rods, and inspect them for any cracks or damage.
3) When installing the side rods, tighten the bolts one turn at a time in a diagonal sequence, not each nut
completely before the next.
4) Use the torque wrench to tighten each nut to their specified torque range.
19
4.5
20
4.6
21
4.7
Wearing parts
1) When damaged or worn, it is highly
recommended to replace the following
wearable parts:
- Tool
- Tool bushing (must be removed at the
service centre)
- Tool pins
- Stopper pin, bushing pin
- Rubber plug, bushing pin plug
- Hydraulic seals
- Side bolts
- Hydraulic hoses
4) Tool pin
- When each tool pin is excessively
deformed, it is difficult to replace the tool.
Therefore, every 100 to 150 hours of
operation, change the face of each pin
which comes in contact with the tool. The
two faces of each pin can be used. If the
tool you use is not a genuine part, we can
not guarantee the breaker unit and parts
performance.
- When replacing each part, check for wear,
breakage, scours, etc., especially after
removing burrs and swelling on tool pins.
- Replace the tool after grinding the worn
parts of the tool pin. Insert a new tool pin
after grinding the scuffed parts of the tool
and tool pins in use.
22
4.8
23
Disassembling
WARNING!
Do not attempt to disassemble or assemble the hammer before reading this chapter of the manual.
1. Disassembly
1)
2)
3)
4)
24
5) Disassemble the cylinder with the eye bolt and by using a hoist or chain block in the
direction indicated by the arrow.
6) Disassemble the piston with the eye bolt vertical, in the direction
indicated by the arrow.
7) Loosen and disassemble the side rod from the front head by screwing
out the quadrangle part with the lower nut by using a spanner.
25
5.2
Assembling
d) Using a rubber hammer assemble the seal
housing into the cylinder.
e) Assemble the back head.
f) Tighten the side rod nuts to their specified
torque.
g) Assemble the removed gas charging valve
and fill the cushion chamber with hydraulic
oil.
h) Tighten the gas charging valve to its
specified torque.
i) Assemble the hose adapter.
1) Seal assembly
Using a brush apply lubrication oil to the seal
groove in order to put in the seals. A lot of care
should be taken when installing seals.
2) General assembly
a) Assemble the side rods to the front head
with the lower nuts.
b) Assemble the cylinder.
c) Lubricate the piston thoroughly and
carefully assemble the piston and the seal
housing. Ensure that the seals are installed
correctly in the cylinder and the seal
housing.
CAUTION!
26
5.3
Torques
Item
N.m
kg.m
ft.lb
2,250
225
1,660
450
45
600
Description
Qty
330
12
60
440
450
45
330
250
25
180
200
20
150
2,500
250
1,845
Joint nut
800
80
590
12
24
5.4
NO.
Part Name
Specifications
Qty
Large Size
Notes
Tool Box
Single Spanner
19mm
Single Spanner
22mm
Single Spanner
32mm
Hammer Wrench
65mm
Hammer Wrench
75mm
L - Wrench
5mm
L - Wrench
10mm
L - Wrench
14mm
10
L Wrench
17mm
11
L Wrench
19mm
12
Driver (+)
1 pc
13
Driver (-)
1 pc
14
Installation Card
2 set
15
2 set
16
Hammer Card
1 set
17
1 set
Option Part
18
Gas Cylinder
3.4 liter
Option Part
19
Seal Kit
1 set
Option Part
25
6. Troubleshooting Guide
6.1
Oil leakage
Probable cause
Remedy
d. Oil leakage between the cylinder and the back - Tighten to specified torque.
head.
6.2
Remedy
26
6.3
No Impact
Probable Cause
Remedy
g. Setting pressure of the relief valve is too low. - Check the pressure of the relief valve.
h. Poor performance of the hydraulic pump.
27
General
Do not use or install the breaker until you can use
the carrier. Do not rush the learning process. Take
your time and learn how to operate the breaker
safely and efficiently.
If there is anything you do not understand, ask
your Vulcan service center for advice.
The breaker serial number is stamped on a metal
plate which is located on the back head near the
inlet connection.
Correct reference to the serial number of the
breaker is important when ordering spare parts.
Identifying parts for specific breakers is only
possible through the serial number.
7.2
Safety
1) Manuals
a. Read this manual before installing, operating,
or maintaining the breaker. If there is anything
that you do not understand ask your employer
or your local Vulcan dealer.
b. Keep this manual in good condition for future
reference.
2) Clothing
a. Proper clothing is important to prevent injury.
Loose clothing can get caught in the machinery
and cause bodily harm.
3) Work site
a. Inspect the working site before starting work.
b. Check for potholes, weak ground, hidden rocks
etc.
c. Check for utilities like water pipes, power lines,
and gas lines.
4) Metal splinters
a. Injury can be caused by flying splinters when
driving metal pins in and out.
b. Always wear safety glasses.
5) Accumulator
a. The accumulator is pressurized even when
there is no hydraulic pressure in the breaker.
28
8. Parts List
8.1
V20GS Housing
32
Part No.
301
Part Name
Qty
Hammer Assembly
A2002410
A2002940
Housing Assembly
303
A2002010
Top Plate
304
A2002020
Wearing Plate
305
A2002030
Wearing Plate
306
A2002040
Wearing Plate
307
A2002050
Wearing Plate
308
A2000180
Top Buffer
309
A2000190
Base Buffer
310
A2000210
311
A2000220
Rubber Plug
312
B1800110
Rubber Plug
313
B4000130
Rubber Plug
314
B3200040
Rubber Grease
A2002070
A2003840
Cover Plate1
A2002080
A2003830
Cover Plate2
317
HB1015020
Bolt
10
318
SW100000
Spring Washer
10
HB2430120
Bolt (Old)
12
HB2430130
Bolt
12
PW240000
Plane Washer
32
NN243000
Nut (Old)
12
HN243000
Nut
32
329
B400W270
Rubber Plug
330
HL11CD-400
Grease Pump
331
SB12175100
Bolt
335
A2001180
Plate (Cover 2)
302
315
316
325
326
328
33
Note
No.
Part No.
336
BHSS-G400
337
Part Name
Qty
Hose
B6000130
Rubber Plug
338
A2005110
Block W.A
339
A3000560
Side Buffer
340
SB2430110
Socket Plug
34
Note
8.2
35
Part No.
A2006010
Back Head
A2006020
Cylinder
A2006030
A2006820
Front Head
A2006040
Seal Housing
A2006050
Piston
A2006060
A2006061
Accumulator Cover
A2006071
A2006830
Accumulator Bottom
A2006080
Upper Bushing
A2006090
Tool Bushing
10
A2006100
Thrust Ring
11
A2006110
Side Rod
A2006120
A2006330
13
A2006130
14
A2006140
15
A2006150
Valve Block
A2006160
A2006320
Valve Cover
17
A2006170
Spool Guide
18
A2006180
Valve Spool
21
A2006210
Tool Pin
22
A2006220
Bushing Pin
23
A2006230
25
A2006250
Connection Bushing
26
A2006260
Plug Bushing
27
A3006270
28
A2006280
Tool Cone
29
A2006290
Tool - Chisel
6
7
12
16
Part Name
36
Qty
Note
Open Type
No.
Part No.
30
A2006300
Tool Blunt
31
A2006310
Adjust Bolt 1
32
A3006320
Adjust Nut 1
33
A3006330
Adjust Bolt 2
34
A3006340
35
A3006350
36
A3006360
A3006370
A3006590
38
A3006380
Heli Coil
39
A3006390
Heli Coil
40
A3006400
Plug
41
A2006360
Guide Pin
43
A2006430
Flange
A2006440
B1306460
Rubber Plug
45
A2006450
Socket Plug
46
A2006460
Membrane
47
B4006450
Socket Plug
50
B4006520
52
B3006560
Grease Nipple
54
B3006570
Snap Ring
58
B3006580
Rubber Plug
HB1016510
A2006510
Head Bolt
60
SB1415035
62
SB1615045
63
SB1815045
12
65
SB2025060
70
SB2430070
75
A2006500
Tool Bushing
37
44
59
Part Name
37
Qty
Note
Box Type
No.
Part No.
76
A2006800
Tool Moil
78
B1006440
Snap Ring
101
B1807100
O - Ring
102
A2007010
Gas Seal
103
A2007020
Step Seal
105
A2007040
O - Ring
106
A2007050
Backup Ring
A2007060
A2107250
Buffer Ring
A2007070
U Packing
A2107260
U Packing
A2007080
Wiper (Old)
A2107270
Wiper
110
B2507190
O - Ring
111
A2007090
Backup Ring
112
B1507200
O - Ring
113
A2007110
O - Ring
A2007120
O Ring (Old)
A3007200
O Ring
A2007130
A3007130
Backup Ring
116
A2007140
O - Ring
117
B1807310
O - Ring
118
A3007160
Backup Ring
119
A3007170
O - Ring
120
A3007180
Backup Ring
121
A3007190
O - Ring
122
A2007150
O - Ring
125
B4007200
O - Ring
126
B6007360
Backup Ring
107
108
109
114
115
Part Name
Qty
38
Note
Box Type
No.
Part No.
Part Name
Qty
127
B6007330
O Ring
128
A2007240
O - Ring
39
Note
8.3
40
Part No.
A2006740
Back Head
A2006750
Cylinder
A2006760
A2006810
Front Head
A2006040
Seal Housing
A2006050
Piston
A2006060
A2006061
Accumulator Cover
A2006071
A2006830
Accumulator Bottom
A2006080
Upper Bushing
A2006090
Tool Bushing
10
A2006100
Thrust Ring
11
A2006110
Side Rod
A2006120
A2006330
13
A2006130
14
A2006140
15
A2006150
Valve Block
16
A2006320
Valve Cover
17
A2006170
Spool Guide
18
A2006180
Valve Spool
21
A2006210
Tool Pin
22
A2006220
Bushing Pin
23
A2006230
25
A2006250
Connection Bushing
26
A2006260
Plug Bushing
27
A2006270
28
A2006280
Tool Cone
29
A2006290
Tool - Chisel
30
A2006300
Tool - Blunt
6
7
12
Part Name
41
Qty
Note
Open Type
No.
Part No.
31
A2006310
Adjust Bolt 1
32
A3006320
Adjust Nut
33
A3006330
Adjust Bolt 2
34
A3006340
35
A3006350
36
A3006360
A3006370
A3006590
38
A3006380
Heli Coil
39
A3006390
Heli Coil
40
A3006400
Plug
41
A2006360
Guide Pin
43
A2006430
Flange
A2006440
B1306460
Rubber Plug
45
A2006450
Socket Plug
46
A2006460
Membrane
47
B4006450
Socket Plug
50
B4006520
52
B3006560
Grease Nipple
54
B3006570
Snap Ring
58
B3006580
Rubber Plug
HB1012510
A2006510
Head Bolt
60
SB1415035
62
SB1615045
63
SB1815045
12
65
SB2025055
70
SB2430070
75
A2006500
Tool Bushing
76
A2006800
Tool Moil
37
44
59
Part Name
42
Qty
Note
Box Type
No.
Part No.
77
A2006470
B2406530
B4006910
Socket Plug
79
A2007230
Grease Nipple
80
BHSSG101
Adapter
101
B1807100
O - Ring
102
A2007010
Gas Seal
103
A2007020
Step Seal
105
A2007040
O - Ring
106
A2007050
Backup Ring
A2007060
A2107250
Buffer Ring
A2007070
U Packing (Old)
A2107260
U Packing
A2007080
Wiper (Old)
A2107270
Wiper
110
B2507190
O Ring
111
A2007090
Backup Ring
112
B1507200
O Ring
113
A2007110
O Ring
A2007120
O Ring (Old)
A3007200
O Ring
A2007130
A3007130
Backup Ring
116
A2007140
O Ring
117
B1807310
O Ring
118
A3007160
Backup Ring
119
A3007170
O Ring
120
A3007180
Backup Ring
78
107
108
109
114
115
Part Name
Qty
43
Note
No.
Part No.
Part Name
Qty
121
A3007190
O Ring
122
A2007150
O - Ring
125
B4007200
O Ring
126
B6007360
Backup Ring
127
B6007330
O Ring
128
A2007220
O Ring
130
B1006440
Snap Ring
132
A2007240
O Ring
44
Note
Specifications
9.1.1
Models
Model: HL11CU-RC400
45
Model: RC400
Cartridge Capacity: 400cc
Model: RC300
Cartridge Capacity: 300cc
46
9.1.2
Diagrams
Model: HL11CU RC400 Diagram
47
48
49
9.1.3
General Specifications
Model: HL11CU RC400
Item
Specifications
Output Pressure
about 10bar
Cylinder Capacity
400 ml
Exterior Size
6.2 kg
Output Port
PF
0.2cc 1cc /min
12cc 60cc /hr
MO2 Grease
NLGI NO.2 (Normal Condition)
NLGI No.1 (Under 10C)
NLGI No.0 (Under 0C)
Output Quantity
Recommended Grease
Available Temperature Range
-10C ~ 50C
-20C ~ 90C
Specifications
Output Pressure
about 10bar
Cylinder Capacity
300 ml
Exterior Size
5.0 kg
Output Port
PF
0.2cc 1cc /min
12cc 60cc /hr
MO2 Grease
NLGI NO.2 (Normal Condition)
NLGI No.1 (Under 10C)
NLGI No.0 (Under 0C)
Output Quantity
Recommended Grease
Available Temperature Range
-10C ~ 50C
-20C ~ 90C
50
9.2
Operation
9.2.1
Grease Filling Procedure Option 1
51
9.2.2
Refilling the Auto Grease Pump can be accomplished one of two ways, the first
way was described on page 8. The second method involves using a manual or
automatic (electric or pneumatic) grease gun and filling the unit through the
Grease Filling Port pictured below.
NOTE: When using the second grease filling method it is extremely important to
ensure that you only fill it up to the fill line, over-filling the unit can cause damage
and failure of the Auto Grease Pump as well as possible personal injury.
52
9.2.3
After the charged cylinder is installed on the main body of the pump check to ensure that the valve of
the cylinder is open and grease is coming out.
The grease moves out of the pump automatically when the breakers operation vibrates the unit.
53
9.3
Features
9.3.1
Benefits
There are many benefits to using the Auto Grease Pump on Vulcan hydraulic breakers, the
following table lists those.
54
9.3.2
Manual Filling
- Manual filling is inconvenient
and wastes the operators time
- Deficient filling causing
excessive injections
- Shortened life of the device
due to improper lubrication
- Environmental pollution
caused by grease spills
Automatic Filling
- Automatic filling is convenient
and does not need constant
attention from the operator
- The pump automatically
dispenses the right amount of
grease to keep the device well
lubricated.
- Increased life of the device
because of proper lubrication
- Less environmental pollution
due to less grease spills
55
9.4
Installation
9.4.1
Model: HL11CU
56
9.4.2
Model: HL11CD
*Vulcan Attachments Inc. is not responsible for errors and omissions to the content of this manual. Specifications are subject to change without notice
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Version: 0711