TD-000-E04
Maverick Hydraulic Hammers Service and Technical Manual
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 1
CONTENTS
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 2
1. About the Hammer 1.1 Definition (mechanism) ............................................................................................................................................. 8 1.2 General composition of the Hammer for use........................................................................................... 8 1.3 General classification of the Hammer ..................................................................................................... 9 2. General specifications 2.1 Standard technical specifications.................................................................................................................. 11 2.2 Dimensions 2.2.1Tool(Rod)....................................................................................................................................................................... 16 2.2.2 Main body(Hammer) .......................................................................................................................................... 19 2.2.3 Bracket(Housing) (1) Silenced type (S-type) ......................................................................................................................... 26 (2) Top type (T-type)..................................................................................................................................... 30 (3) Side type (H-type) ................................................................................................................................... 33 (4) Back hoe type (B-type)....................................................................................................................... 35 (5) Uniram type (U-type)............................................................................................................................. 36 2.2.4 Top plate ..................................................................................................................................................................... 37 3. Structural view of the hammers 3.1 350, 400, 500, 750, 1000, 1500, 2250,
3250 .............................................................................. 43
3.2 6250 ................................................................................................................................................................................ 44 3.3 4750, 5250, 8250, 9250 .................................................................................................................................... 45 4. Functions of the main components 4.1 350, 400, 500, 750, 1000, 1500, 2250, 3250 ...................................................................................... 47 4.2 6250 ................................................................................................................................................................................ 48 4.3 4750, 5250, 8250, 9250 .................................................................................................................................... 49 4.4 Valve system ............................................................................................................................................................. 50 5. Principle of operation 5.1 350, 400, 500, 750, 1000, 1500, 2250, 3250, 6250 Introduction .......................................................................................................................................................... 52 Piston start up (Return stroke) ............................................................................................................... 53 Valve changing................................................................................................................................................. 54 Impact stroke ...................................................................................................................................................... 55 5.2 4750, 5250, 8250, 9250 Introduction ..........................................................................................................................................................57 Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 3
Maverick Hammers - U.S.A. CONTENTS 6.16 Disassembly and assembly of the valve and valve plug ......................................................... 77 6.17 Disassembly and assembly of the valve housing ........................................................................... 78 6.18 Disassembly and assembly of the accumulator adjuster ......................................................... 79 6.19 Disassembly and assembly of the accumulator cover ........................................................... 80 6.20 Disassembly and assembly of the accumulator bottom ............................................................ 81 6.21 Disassembly and assembly of the cylinder adjuster ....................................................................... 82 6.22 Disassembly and assembly of the air vent ........................................................................................... 83 6.23 Disassembly and assembly of the seal in the seal housing ...................................................... 84 6.24 Disassembly and assembly of the seal in the cylinder ................................................................. 85 6.25 Disassembly and assembly of the silencing parts ............................................................................ 86 7. Torque references 7.1 350, 400, 500................................................................................................................................................................ 88 7.2 750, 1000, 1500, 2250, 3250............................................................................................................................. 89 7.3 4750, 5250, 6250, 8250, 9250.......................................................................................................................... 90 8. Valve adjuster control ........................................................................................................................................................ 92 9. Tool 9.1 Replacement of the tool .................................................................................................................................. 94 9.2 How to use tools properly .................................................................................................................................... 95 10. How to charge N2 gas 10.1 Gas charging to the back-head ........................................................................................................... 100 10.2. Gas charging to the accumulator. ........................................................................................................ 102
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 4
1. ABOUT THE Hammer
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 5
1.1 Definition ( mechanism ) The Hammer is the hammering implement using movement energy transformed from electric, hydraulic, pneumatic energy, etc each by mechanical tools, hydraulic circuit, pneumatic circuit mechanism. The Hammer is used for various purposes, for example, to crush and demolish rocks in quarries and mines or for building dismantling works, pavement breaking and so on with mounting it on the excavator. The Hammer was first developed for pneumatic system using only compressed air. After then, it has been developed for hydraulic system using hydraulic oil supported from the hydraulic pump of the excavator and now being in use with mixture system of nitrogen gas and hydraulic pressure as designed for less consuming of the hydraulic oil, high efficiency and more lightening in weight in order to minimize any possible damage on the excavator’s unit. (hydraulic pump) 1.2 General composition of the Hammer for use A) Main body parts B) Piping parts C) Bracket parts D) Hydraulic unit (Power units)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 6
1.3 General classification of the Hammer 1.3.1 According to the source of the power supply - Spring type - Air pressure type - Gas pressure type - Diesel engine type - Hydraulic pressure type - Gas + Hydraulic pressure type
1.3.1 According to the mounting angle to the excavator - TOP TYPE : mounting part is above housing - SIDE TYPE : mounting part is beside housing
Maverick Hammers - U S A
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 7
2 . G E N E R A L S P E C I FI C A T I O N S
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 8
Maverick Hammers - U.S.A. Standard Technical Specifications MODEL Number of strike
350
400
500
(bpm)
800 - 1,350
650 - 1,200
550 - 1,100
bar
110 - 140
110 - 140
110 - 140
Pressure Relief
(psi)
1,564 - 1,992
1,564 - 1,992
1,564 - 1,992
Operating pressure (Hammer)
bar
90 - 120
90 - 120
90 - 120
(psi)
1,280 - 1,707
1,280 - 1,707
1,280 - 1,707
bar
13 - 15
13 - 15
13 - 15
(psi)
185 - 213.4
185 - 213.4
185 - 213.4
bar
-
-
-
Back head pressure
Accumulator pressure
(psi)
-
-
-
Oil flow
lpm
15 - 30
20 - 40
25 - 50
HYD. Oil temperature
(°C)
(-20) - (+80)
(-20) - (+80)
(-20) - (+80)
HYD. Oil viscosity
(CST)
15-1,000
15-1,000
15-1,000
IN (INCH)
3/8“
3/8“
1/2“
OUT (INCH)
3/8“
3/8“
1/2“
ton
0.8 - 2.5
1.2 - 3
2.5 - 4.5
(lbs)
1,600-5,000
3,000-7,000
6,000-10,000
mm
36
45
(INCH)
1.57
1.77
Line size
Carrier Weight
Tool shank diameter
53 2.08
* The above specifications are subject to change without prior notice for the quality enhancement.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 9
Maverick Hammers - U.S.A. Standard technical specifications MODEL
750
1000
1500
(bpm)
500 - 1,000
450 - 1,000
475 - 950
bar
110 - 140
120 - 150
130 - 160
(psi)
1,564 - 1,992
1,396 - 1,745
1,513 - 1,862
Operating Pressure
bar
90 - 120
100 - 130
110 - 140
(Hammer)
(psi)
1,280 - 1,707
1,422 - 1,849
1,564 - 1,992
bar
13-15
13-15
13-15
(psi)
185-213.4
185-213.4
185-213.4
bar
-
-
-
(psi)
-
-
-
Oil flow
lpm
30 - 60
40 - 70
50 - 90
HYD. Oil Temperature
(°C)
(-20) - (+80)
(-20) - (+80)
(-20) - (+80)
HYD. Oil viscosity
(CST)
15 - 1,000
15 - 1,000
15 - 1,000
1/2“
1/2“
1/2“
Line Size
IN (INCH) OUT (INCH)
1/2“
1/2“
1/2“
ton
3 - 5.5
5-8.5
7-9.5
(lbs)
7,000-12,000
10,000-17,000
14,000-19,000
mm
60
68
75
(inch)
2.36
2.67
2.95
Number of strike Pressure Relief
Back Head Pressure
Accumulator pressure
Carrier Weight
Tool shank diameter
* The above specifications are subject to change without prior notice for the quality enhancement.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 10
Maverick Hammers - U.S.A. Standard technical specifications MODEL
2250
3250
4750
(bpm)
480 - 850
480 - 780
350 - 750
bar
140 - 170
150 - 180
160 - 190
(psi)
1,992 - 2,418
2,134 - 2,561
2,276 - 2,703
Operating pressure
bar
120 - 150
130 - 160
140 - 170
(HAMMER)
(psi)
1,707 - 2,134
1,850 - 2,276
1,992 - 2,418
Number of strike Pressure Relief
bar
15 - 17
15 - 17
5-7
(psi)
213.4 - 241.8
213.4 - 241.8
73 - 102
bar
-
-
55
(psi)
-
-
782
Oil flow
lpm
60 - 100
80 - 110
90 - 120
HYD. Oil temperature
(°C)
(-20) - (+80)
(-20) - (+80)
(-20) - (+80)
HYD. Oil viscosity
(cST)
15 - 1,000
15 - 1,000
15 - 1,000
3/4“
3/4“
1"
3/4“
3/4“
1"
ton
8-12
11-19
14 - 19
(lbs)
16,000-24,000
22,000-38,000
35,000-48,000
Back head pressure
Accumulator pressure
IN Line size
( inch ) OUT ( inch )
Carrier weight
Tool shank diameter
mm
85
100
120
(inch)
3.35
3.94
4.72
* The above specifications are subject to change without prior notice for the quality enhancement.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Standard technical specifications MODEL
5250
6250
8250
(bpm)
300 - 600
280 - 500
300 - 400
bar
180 - 200
180 - 200
180 - 200
(psi)
2,561 - 2,846
2,561 - 2,846
2,561 - 2,846
Operating pressure
bar
160 - 180
160 - 180
160 - 180
(HAMMER)
(psi)
2,276 - 2,561
2,276 - 2,561
2,276 - 2,561
bar
5-7
5-7
5-7
(psi)
73 - 102
213.4 - 241.8
73 - 102
bar
55
55
55
(psi)
782
782
782
Oil flow
lpm
120 - 150
120 - 150
160 - 190
HYD. Oil temperature
(°C)
(-20) - (+80)
(-20) - (+80)
(-20) - (+80)
HYD. Oil viscosity
(cST)
15 - 1,000
15 - 1,000
15 - 1,000
1“
1“
1“
1“
1“
1“
ton
18 - 26
20 - 28
27 - 36
(lbs)
38,000-54,000
42,000-65,000
72,000-105,000
mm
135
140
150
(inch)
5.31
5.51
5.9
Number of strike Pressure Relief
Back head pressure
Accumulator pressure
IN Line size
( inch ) OUT ( inch )
Carrier weight
Tool shank diameter
* The above specifications are subject to change without prior notice for the quality enhancement.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 12
Maverick Hammers - U.S.A. Standard technical specifications MODEL
9250
10,000
(kg)
2,650
3,750
lbs
5,830
8,250
(bpm)
260 - 400
200 - 350
bar
180 - 210
180 - 210
(psi)
2,560 - 2,987
2,560 - 2,987
Operating pressure
bar
160 - 190
160 - 190
(HAMMER)
(psi)
2,275 - 2,702
2,275 - 2,702
bar
15 - 17
17.5-250
(psi)
213.4 - 241.8
73 - 102
bar
60
60
(psi)
870
870
Oil flow
lpm
190 - 250
210 - 290
HYD. Oil temperature
(°C)
(-20) - (+80)
(-20) - (+80)
HYD. Oil viscosity
(cST)
15 - 1,000
15 - 1,000
1-1/4“
1-1/4“
1-1/4“
1-1/4“
ton
35 - 50
45 - 60
(lbs)
72,000-105,000
88,000-110,000
mm
160
180
(inch)
6.3
7.08
Operating Weight Number of strike Pressure Relief
Back head pressure
Accumulator pressure
IN Line size
( inch ) OUT ( inch )
Carrier weight
Tool shank diameter
* The above specifications are subject to change without prior notice for the quality enhancement.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 13
Maverick Hammers - U.S.A. Dimensions - Tool -
BLUNT
CONICAL
model
WEDGE
MOIL POINT
350
400
standard
BLUNT
CONICAL
Length (mm)
400
400
400
Weight ( kg )
3
2.8
Diameter (mm)
Φ36
Φ36
model
WEDGE MOIL
BLUNT
CONICAL
WEDGE
MOIL
400
460
460
460
460
2.9
2.8
5.4
5
5.2
5
Φ36
Φ36
Φ45
Φ45
Φ45
Φ45
500
750
standard
BLUNT
CONICAL
Length (mm)
500
500
500
Weight (kg)
8.1
7.2
Diameter (mm)
Φ53
Φ53
model
WEDGE MOIL
BLUNT
CONICAL
WEDGE
MOIL
500
500
500
500
500
7.7
7.4
10.1
8.9
9.5
9.1
Φ53
Φ53
Φ60
Φ60
Φ60
Φ60
1000
1500
standard
BLUNT
CONICAL
WEDGE MOIL
BLUNT
CONICAL
WEDGE
MOIL
Length (mm)
690
690
690
690
750
750
750
750
Weight (kg)
18.7
17.1
17.9
17.4
24.7
22.9
23.5
22.8
Diameter (mm)
Φ68
Φ68
Φ68
Φ68
Φ75
Φ75
Φ75
Φ75
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 14
Maverick Hammers - U.S.A. Dimensions - ToolS -
BLUNT model standard Length (mm) Weight ( kg ) Diameter (mm) model standard Length (mm) Weight (kg) Diameter (mm) model standard Length (mm) Weight (kg) Diameter (mm)
BLUNT
CONICAL 2250 CONICAL WEDGE
WEDGE
MOIL
BLUNT
MOIL POINT 3250 CONICAL WEDGE
MOIL
800
800
800
800
1,000
1,000
1,000
1,000
33.9
30.2
31.8
30.7
58
53.2
55.3
53.6
Φ85
Φ85
Φ85
Φ85
Φ100
Φ100
Φ100
Φ100
BLUNT
6250 CONICAL WEDGE
MOIL
BLUNT
9250 CONICAL WEDGE
MOIL
1,248
1,248
1,248
1,248
1,500
1,500
1,500
1,500
143.6
127
134.3
129.1
209.2
190.2
199
192.8
Φ140
Φ140
Φ140
Φ140
Φ160
Φ160
Φ160
Φ160
10,000H BLUNT
CONICAL
WEDGE
MOIL
Φ180
Φ180
Φ180
Φ180
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 15
Maverick Hammers - U.S.A. Dimensions - Tools-
BLUNT
CONICAL
model
WEDGE
4750
MOIL POINT 5250
standard
BLUNT
CONICAL
WEDGE
MOIL
BLUNT
CONICAL
WEDGE
MOIL
Length (mm)
1,100
1,100
1,100
1,100
1,200
1,200
1,200
1,200
Weight (kg)
95.3
87.1
91.1
88.3
126
113.7
119.5
115.5
Diameter (mm)
Φ120
Φ120
Φ120
Φ120
Φ135
Φ135
Φ135
Φ135
model
8250
standard
BLUNT
CONICAL
WEDGE
MOIL
Length (mm)
1,300
1,300
1,300
1,300
Weight (kg)
174.9
159.4
170.8
161.6
Diameter (mm)
Φ150
Φ150
Φ150
Φ150
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 16
Maverick Hammers - U.S.A. Dimensions - Main Body (Hammer) 350
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
400
Page 17
Maverick Hammers - U.S.A. Dimensions ( 500
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
) 750
Page 18
Maverick Hammers - U.S.A. Dimensions - Main Body (Hammer) -
1000
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
1500
Page 19
Maverick Hammers - U.S.A. Dimensions - Main Body (Hammer) -
2250
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
3250
Page 20
Maverick Hammers - U.S.A. Dimensions - Main Body (Hammer) 4750
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
5250
Page 21
Maverick Hammers - U.S.A. Dimensions Main Body (Hammer) 6250
8250
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 22
Dimensions - Main Body (Hammer) 9250
10,000
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 23
Dimensions Main Bracket - Silenced type (S-type) -
(mm)
350HSP
400HSP
500HSP
750HSP
B1
175
186
190
212
B2
220
228
246
272
H1
202.5
211.5
215.5
240
H2
280
293
302
345
T1
20
20
20
25
T2
14
14
16
16
L0
963
1073
1133
1142
L1
214.5
279
285
284
L2
716.5
762
813
823
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 24
Maverick Hammers - U.S.A. Dimensions Main Bracket - Silenced type (S-type) -
(mm)
1000HSP
1500HSP
2250HSP
3250HSP
B1
260
260
260
320
B2
390
390
400
500
H1
295
325
340
390
H2
420
420
470
520
T1
36
40
40
40
T2
19
20
20
25
L0
1452
1463.5
1781
2024
L1
369
317.5
426
531
L2
1029
1094
1339
1477
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 25
Maverick Hammers - U.S.A. Dimensions Main Bracket - HSP Models - Silenced type-
(mm)
4750HSP
5250HSP
6250HSP
8250HSP
B1
370
404
410
425
B2
550
560
560
630
H1
425
480
540
500
H2
650
700
730
700
T1
40
40
40
50
T2
28
28
28
32
L0
2141
2397
2466
2621
L1
667
747
675
779
L2
1455
1632
1773
1824
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 26
Maverick Hammers - U.S.A. Dimensions Main Bracket - HSP Models - Silenced type -
(mm)
9250HSP
B1
465
B2
700
H1
550
H2
830
T1
50
T2
35
L0
2990
L1
856.5
L2
2110
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 27
Maverick Hammers - U.S.A. Dimensions Main Bracket - HP Models -
(mm)
1000HP
1500HP
2250HP
3250HP
B1
296
316.5
330
386
B2
390
390
400
500
H1
420
420
470
520
T1
19
19
20
25
L0
1,426
1,453.5
1,828
2,030
L1
415
368.5
465
561
L2
955
1,069
1,347
1,453
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 28
Maverick Hammers - U.S.A. Dimensions Main Bracket - HP Models -
(mm)
4750HP
5250HP
8250HP
9250HP
B1
412
447
482
538
B2
550
560
630
700
H1
500
540
575
685
H2
650
700
700
830
L0
2,137
2,451.5
2,608
3,037
L1
669
783.5
754
861.5
L2
1,449
1,650
1,854
2,152
T1
40
40
50
50
T2
28
30
32
36
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 29
Maverick Hammers - U.S.A. Dimensions Main Bracket - HP Models -
(mm)
6250HP
10,000HP
B1
447
TBD
B2
560
H1
590
H2
730
T1
2456
T2
670
L0
1,768
L1
40
L2
28
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 30
Maverick Hammers - U.S.A. Dimensions Main Bracket - Side type(H-type) -
(mm)
1000LBH
1500LBH
2250LBH
3250LBH
B0
180
220
226
320
B1
258
310
328
422
B2
294
331
356
422
H1
690
725
854
1067.5
H2
260
290
340
380
L0
1356
1388.5
1737.5
1969
L1
941
1020
1263
1408
D
60
65
75
80
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 31
Maverick Hammers - U.S.A. Dimensions Main Bracket - Side type(H-type) -
(mm)
4750LBH
5250LBH
6250LBH
8250LBH
9250LBH
B0
418
447
447
482
512
B1
350
350
350
440
440
B2
480
490
490
600
600
H0
625
650
597
585
685
H1
460
450
450
480
570
H2
1202.5
1217
1238
1376
1464
L0
2042
2303
2366
2516
2843.5
L1
1345
1565
1696
1712
1982
T
40
40
40
50
50
D
Φ100
Φ100
Φ100
Φ120
Φ120
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 32
Maverick Hammers - U.S.A. Dimensions Main Bracket - HLB - Back hoe type-
(mm)
400
500
750
1000
1500
B1
380
380
B2
623
679
H1
260
260
H2
324
324
H3
378
378
L0
1671
1665.5
L1
1236
1297
D
60
60
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 33
Maverick Hammers - U.S.A. Dimensions Main Bracket - Uniram type(U-type) -
(mm)
400
500
750
1000
1500
B1
195
1210
1278
280
1591.5
B2
300
887
951
420
1223
H1
130
215
280
175
290
H2
188
339
416
235
440
H3
193
154
175
274
220
L0
1129.5
214
235
1555
310
L1
812.5
227
277
1120
339.5
D
Φ45
Φ65
Φ60
Φ60
Φ65
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 34
Maverick Hammers - U.S.A. Dimensions Top plate
(mm)
350
400
500
L0
280
293
302
L1
15
15
18
L2
125
131.5
133
L3
125
131.5
133
H0
220
228
246
H1
16
16
18
H2
95
99
105
H3
95
99
105
D
15
15
18
R
5
5
5
T
14
14
14
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 35
Maverick Hammers - U.S.A. Dimensions Top plate
(mm)
750
L0
345
L1
18
L2
103
L3
103
L4
103
H0
272
H1
18
H2
118
H3
118
D
18
R
5
T
16
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Dimensions
Top plate
(mm)
1000
1500
2250
3250
L0
420
420
470
520
L1
25
25
25
25
L2
115
115
140
150
L3
140
140
140
170
L4
115
115
140
150
H0
390
390
400
500
H1
25
25
25
25
H2
105
105
120
150
H3
130
130
110
150
H4
105
105
120
150
D
23
23
23
23
R
20
20
20
20
T
19
19
19
25
\
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Dimensions Top plate
(mm)
4750
5250
6250
8250
L0
650
700
730
700
L1
30
30
30
30
L2
200
215
230
215
L3
190
210
210
210
L4
200
215
230
215
H0
550
560
560
630
H1
30
30
30
30
H2
150
165
165
180
H3
190
170
170
210
H4
150
165
165
180
D
27
27
27
27
R
25
25
25
25
T
30
30
28
32
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Dimensions
Top plate
(mm)
9250
L0
830
L1
35
L2
190
L3
190
L4
190
L5
190
H0
700
H1
35
H2
190
H3
250
H4
190
D
33
R
30
T
35
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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3.STRUCTURAL VIEW OF THE HAMMERS
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 40
Main body structural view (350, 400, 500, 750, 1000, 1500, 2250, 3250)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Main body structural view (6250)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Main body structural view (4750, 5250, 8250, 9250, 10,000, 12,000, 15,000)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A.
4.FUNCTIONS OF THE MAIN COMPONENTS
M
i kH
USA
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Functions of main components (350, 400, 500, 750, 1000, 1500, 2250, 3250)
Through Bolt The Front head, the cylinder and the Back-Head of the main body are tightly fixed with four through bolts.
Back-Head The Gas charging valve is built in and the inside is charged with N2-gas.
Valve System The Cylindrical control valve is built in the valve housing and controls piston reciprocation.
Piston Kinetic energy of the piston is converted into hammering energy after hitting the Tool. The hammering energy transmitted to the Tool breaks rocks.
Front Head The front head supports the whole Hammer. The Thrust ring and the thrust bushing prevents shock from the Tool.
Tool The specially heat-treated Tool is directly applied to break rocks. It is used as moil point, wedge point and flat Tool according to the application (optional).
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 45
Maverick Hammers - U.S.A. Functions of main components (6250)
Through Bolt The Front head, the cylinder and the Back-Head of the main body are tightly fixed with four through bolts.
Back-Head The Gas charging valve is built in and the inside is charged with N2-gas.
Valve System The Cylindrical control valve is built in the valve housing and controls piston reciprocation.
Piston Kinetic energy of the piston is converted into hammering energy after hitting the Tool. The hammering energy transmitted to the Tool breaks rocks.
Front Head The front head supports the whole Hammer. The Thrust ring and the thrust bushing prevent shock from the Tool.
Tool The specially heat-treated Tool is directly applied to break rocks. It is used as moil point, wedge point and flat Tool according to the Application (optional).
Accumulator Ass'y The accumulator compensates for pressure in the hydraulic circuit and prevents pulsation. It is not usually necessary to refill. Use N2-gas only.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 46
Maverick Hammers - U.S.A. Functions of main components (4750, 5250, 8250, 9250, 10,0o00, 12,000. 15,000)
Through Bolt The Front head, the cylinder and the Back-Head of the main body are tightly fixed with four through bolts. Back-Head The Gas charging valve is built in and the inside is charged with N2-gas. Valve System The Cylindrical control valve is built in the valve housing and controls piston reciprocation. Piston Kinetic energy of the piston is converted into hammering energy after hitting the Tool. The hammering energy transmitted to the Tool breaks rocks. Front Head The front head supports the whole Hammer. The Thrust ring and the thrust bushing prevents shock from the Tool. Tool The specially heat-treated Tool is directly applied to break rocks. It is used as moil point, wedge point and flat Tool according to the application(optional). Accumulator Ass'y The accumulator compensates for pressure in the hydraulic circuit and prevents pulsation.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Valve system VALVE SYSTEM
V/V SLEEVE (V/V HOUSING)
VALVE
VALVE PLUG
VALVE COVER
(350, 400, 500, 750, 1000, 1500, 2250,3250,10,000H)
( 6250 )
( 4750, 5250, 8250, 9250 )
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A.
5.PRINCIPLE OF OPERATION
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 49
Introduction (350 - 3250, 6250)
The relation between the pressure affected area A₁ of the piston rear chamber and the pressure affected area A1 of the piston front chamber is A₁> A₂. High-pressure oil is always applied to A1and, when oil pressure applied to A₁ is changed from high to low pressure and vice versa, piston C₂ reciprocates. Similarly the relation between the pressure affected area A₃ of the valve high-pressure chamber and the pressure affected area A₄> A₃. High-pressure oil is always applied to A₃ and, when the oil pressure applied to A₄ is changed from high to low pressure and vice versa, valve C₄ changes to alter the port to the piston rear chamber B₁ from the high-pressure side to the low-pressure side and vice versa and, in accordance with the reciprocation of valve C₄, piston C₂ reciprocates. Further the back head is charged with N₂ gas. When the piston moves backward, the N₂ gas is compressed to store the gas energy and, when the piston hammers, the gas energy is converted into piston hammering energy.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Piston start up (Return stroke) (350 - 3250, 6250)
When high-pressure oil is applied to the IN port of the hydraulic Hammer, the high-pressure oil acts upon the piston front chamber A₂ and valve high-pressure chamber V₁ to hold down the valve. As the piston rear chamber B₁ is connected to the OUT port through the valve, The piston C₂ starts moving backward under the high-pressure oil applied to the pressure affected area A₂ of the piston front chamber.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Valve changing (350 - 3250, 6250)
When the piston moves backward, The high-pressure oil acts upon the valve change V1 and the valve changes. At this time, the piston rear chamber B₠is disconnected from the valve lowpressure chamber V₃ and connected to the valve high-pressure chamber B 3 and pressure in the piston rear chamber B₠increases.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Impact stroke (350 ~ 3250, 6250)
When the piston Câ‚‚ reaches top high-pressure oil from the valve high-pressure chamber B 3 acts upon the piston rear chamber Bâ‚ . At the same time the piston moves forward and impacts the tool. The valve is held open because high-pressure chamber Vâ‚
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Introduction (4750, 5250, 8250, 9250, 10,000, 12,000, 15,000)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 54
Maverick Hammers - U.S.A. Introduction (4750, 5250, 8250, 9250, 10,000, 12,000, 15,000)
The relation between the pressure affected area A1 of the piston rear chamber and the pressure affected are A2 of the piston front chamber is A1>A2. High-pressure oil is always applied to A2 and, when oil pressure applied to A1 is changed from high to low pressure and vice versa, piston C2 reciprocates. Similarly the relation between the pressure affected area A3 of the valve high-pressure chamber and the pressure affected are A4>A3. High-pressure oil is always applied to A3, A4 and A3<A4. Therefore, the Valve is move the A4 side and vice versa, valve C4 changes to alter the port to the piston rear chamber B1 from the highpressure side to the low-pressure side and vice versa and, in accordance with the reciprocation of valve C4, piston C2 reciprocates. Further the Back-Head is charged with N2-gas. When the piston moves backward, the N2-gas is compressed to store the gas energy and, when the piston hammers, the gas energy is converted into piston hammering energy.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Piston start up (Return stroke) (4750, 5250, 8250, 9250, 10,000, 12,000, 15,000)
When high-pressure oil is applied to the IN port of the hydraulic Hammer, the high-pressure oil acts upon the piston front chamber A2 and valve high-pressure chamber V1 to hold down the valve. As the piston rear chamber B1 is connected to the OUT port through the valve and changed to the low-pressure side, piston C2 start moving backward under the high-pressure oil applied to the pressure affected area A2 of the piston front chamber. At this time, N2-gas in the Back-Head is compressed.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 56
Maverick Hammers - U.S.A. Valve changing (4750, 5250, 8250, 9250, 10,000, 12,000, 15,000)
When the piston moves backward and the piston rear chamber B1 is connected to the valve change port B3, the high-pressure oil acts upon the valve change chamber V4 and the valve changes. At this time, the piston rear chamber B1 is disconnected from the valve low-pressure chamber V3 and connected to the valve high-pressure chamber V1 and pressure in the piston rear chamber B1 increase.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 57
Maverick Hammers - U.S.A. Impact stroke ( 4750, 5250, 8250, 9250 )
When piston C2 reaches top dead center, high-pressure oil from the valve high-pressure chamber V1 acts upon the piston rear chamber B1 and the hammering stroke. Converted into the compressed gas energy in the Back-Head. The valve is held open because high-pressure chamber V1 and valve change chamber V4.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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6.DISASSEMBLy and ASSEMBLy OF THE HAMMER
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Disassembly and assembly of the plug
When removing the rubber cap from bracket, insert the long nose ripper to the groove of rubber cap and pull out the rubber cap in slide.
Pull out rubber cap using screwdriver or end-pointed instruments. Disassemble Rubber cap.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembly and assembly of the tool pin and stop pin Insert the pin into the rubber cap hole and hit the pin using a handle hammer. Remove the stop pin.
Push up the tool pin using pin, and take out the tool pin.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembly and assembly of the tool Set the nylon sling in the center of the tool and lift it a little and remove the tool slowly.
Disassemble bolts and nuts of cover plate using spanner and pipe. Remove the cover plate. Take out upper damper.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Removal of the main body(hammer) Disassemble support bolts
Install the eye bolt on the back head and lift the main body.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembly and assembly of the wear plates
Disassembly of the wearing plate and bottom plate
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Back-head N2 gas charging 1) Discharge of N2 gas in the back head. · N₂ gas inside Back head should be completely removed. If not so, explosion may occur, when through bolt is loosened. · Notice the procedure following the gas pressure. 2) Charge of N2 gas in the back head · Install charging adapter on charging valve of back head in connection of N₂ gas bottle charge back head with N₂ gas. · Insert charging valve cap of back head.
Used tools
! WARNING
*Spanner 17 x 19mm
*N₂ bottle Charging device set.
Do not attempt to disassemble or assemble without discharging
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Loosening and tightening of the through bolt
1) Loosening 路Through bolt & Nut can be disconnected in use of power wrench or, hammer wrench Can be used Not loosening it completely, but do only until it can be turned with hand.
2) Tightening 路Clean the through bolt and the contact surface of the through bolt. 路Grease the screw threads of through bolt. 路Tighten it at a half degree a regular torque toward the diagonal direction. Tighten it at a regular torque.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembling and assembling of the back-head
1) Disassembly - Separate back head in use of hoist or chain block. - Take out O-ring.
2) Assemble - Put O-ring to back head fit O-ring to the top of cylinder and - Insert joint ring into the top of back head connect in with cylinder, using hoist or chain block apply grease to it
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Maverick Hammers - U.S.A. Disassembling and assembling of the piston and the seal housing 1) Disassembling of piston and seal housing · Lifting eyes on Piston · Lift piston upward from Cylinder carefully, and it could be laid according to job site situation. ·Stand Piston removed, and separate Seal housing from Piston topping the lower part of Seal housing in use of rubber hammer. · Screw M16 Lifting bolts on Cylinder, and lift carefully upwards to be laid, using hoist or chain block.
2) Assembling of piston and seal housing ·Lift Cylinder to fit into Front head. · Put it into Cylinder slowly, lifting with Hoist or Chain block. ·When Seal housing is inserted, Plastic or Rubber hammer should be used. And strike it, putting on rubber plate.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembling and assembling of the cylinder assy.
1) Disassembling and assembling - Set the nylon sling to the bolts on both sides of the cylinder and lift the cylinder. While lifting it, insert the pipe into the tie rod hole and lay it down.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembling and assembling of the tool bush 1) Disassembling a) Remove the locking pin A. b) Remove the tool bushing B from the front head, using sleeve puller. c) If tool bushing is tight, warm the under part of the front head. d) Check tool and tool bushing for wear
2) Assembling a) Clean all parts. b) Apply Mo S2 spray to the contact surface of Tool bushing and Front head. c) Install Tool bushing B d) Install locking pin A.
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Maverick Hammers - U.S.A. Disassembling and assembling of the thrust bush
1) Disassembling a) Remove the locking pin A. b) Remove the tool bushing B from the front head, using sleeve puller. c) If tool bushing is tight, warm the under part of the front head. d) Check tool and tool bushing for wear
2) Assembling a) Clean all parts. b) Apply Mo S2 spray to the contact surface of Tool bushing and Front head. c) Install Tool bushing B d) Install locking pin A.
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Maverick Hammers - U.S.A. Disassembling and assembling of the valve adjuster nut Lay down the cylinder on wood blocks carefully.
Disassemble the valve adjuster using a spanner.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembling and assembling of the valve adjuster and valve cover Disassemble the adjuster using a L-wrench. Pull out the adjuster from the valve
Loosen the socket bolts of the valve housing using a L-wrench. Disassemble the valve housing cover and check the back-up ring and the o-ring.
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Maverick Hammers - U.S.A. Disassembling and assembling of the valve plug and valve
After disassembling the cover, and pull out the valve plug carefully.
After disassembling the valve plug, and take out the valve carefully.
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Maverick Hammers - U.S.A. Disassembling and assembling of the valve housing Disassemble the valve housing using a L-wrench.
Remove all socket bolts and disassemble the valve housing using eye bolts. Check the back-up ring and the o-rings on the bottom side of the cylinder.
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Maverick Hammers - U.S.A. Disassembling and assembling of the accumulator adjuster Before disassembling the accumulator, disassemble the upper cap to discharge the gas.
(If the gas was not discharged completely, it may be dangerous.) Remove the gas charging valve cap using a spanner. Using a L-wrench, discharge the gas slowly and carefully. (If the gas was left inside, of the accumulator it would be very dangerous. So, the gas should be discharged completely.)
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Maverick Hammers - U.S.A. Disassembling and assembling of the accumulator cover and diaphragm Disassemble upper cover bolts using a L-wrench.
After disassembling the socket bolts, pull up the accumulator cover and remove it using a eye bolt.
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Maverick Hammers - U.S.A. Disassembling and assembling of the accumulator bottom After disassembling the socket bolts, pull up the accumulator cover and remove it using a eye bolt.
Loosen the accumulator body bolts using an L-wrench.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Disassembling and assembling of the cylinder adjuster Disassemble the cylinder adjuster nut using a spanner
Disassemble the cylinder adjuster using a spanner
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Page 79
Maverick Hammers - U.S.A. Disassembling and assembling of the Air Valve
Disassemble the air check valve using a spanner.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 80
Maverick Hammers - U.S.A. Disassembling and assembling of the seal in the seal housing
1) Disassembly When Packing, all kind of O-ring are disassembled, be careful not to damage them.
2) Assembly of Seal housing Assembly of Packing Assemble it, by paying attention to the direction on Packing to be set.
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Maverick Hammers - U.S.A. Disassembling and assembling of Seals
1) Disassembly Remove Seal from Cylinder carefully, using tool for disconnecting Seal. 2) Assembly Brush hydraulic oil over the part that Seal is set and fit Packing. Fit Packing and check they are in good fitness. And then, apply grease over the part.
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Maverick Hammers - U.S.A. Disassembling and assembling of the silencing parts 1) Disassembling a. Remove the plug A, C, E, F, G Housing. b. Disassemble the IN-OUT hoses from The Hammer. c. Remove the cover B and D d. Remove the tool.
2) Assembling a. Install cover C b. Assemble the IN-OUT hoses from The Hammer. c. Install the plug A, B, D, E, F, G into housing
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Maverick Hammers - U.S.A.
7.TORQUE REFERENCES
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Maverick Hammers - U.S.A. Torque references
Model
Unit
350
400
500
Through Bolt
Kg.m
40
40
40
Charging Valve
Kg.m
35
35
35
Side Bolt
Kg.m
100
100
100
Mount Cap
Kg.m
-
-
-
Flange Adapter Bolt
Kg.m
-
-
-
Valve Cover Bolt
Kg.m
-
-
-
Valve Body Bolt
Kg.m
-
-
-
Acc' Body
Kg.m
-
-
-
Acc' Cover
Kg.m
-
-
-
Divide
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Maverick Hammers - U.S.A. Torque references
Model
Unit
750
1000
1500
2250
3250
Through Bolt
Kg.m
40
40
40
100
150
Charging Valve
Kg.m
35
35
35
35
35
Side Bolt
Kg.m
100
100
100
145
170
Mount Cap
Kg.m
-
-
-
-
-
Flange Adapter Bolt
Kg.m
-
-
-
-
-
Valve Cover Bolt
Kg.m
-
-
-
-
-
Valve Body Bolt
Kg.m
-
-
-
-
-
Acc' Body
Kg.m
-
-
-
-
-
Acc' Cover
Kg.m
-
-
-
-
-
Divide
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Maverick Hammers - U.S.A. Torque references
MOUNTING BOLT
MOUNTING BOLT
THROUGH BOLT
THROUGH BOLT
FLANGE BOLT
VALVE COVER BOLT FLANGE BOLT VALVE BOX BOLT
ACCUMULATOR BODY BOLT ACCUMULATOR BODY BOLT
ACCUMULATOR COVER BOLT
ACCUMULATOR COVER BOLT
SIDE BOLT
Model
SIDE BOLT
Unit
4750
5250
6250
8250
9250
Through Bolt
Kg.m
175
225
270
250
360
Charging Valve
Kg.m
35
35
35
35
35
Side Bolt
Kg.m
200
250
250
305
360
Mounting Cap
Kg.m
130
150
150
160
220
Flange Adapter Bolt
Kg.m
20
20
35
20
20
Valve Cover Bolt
Kg.m
60
60
-
45
45
Valve Body Bolt
Kg.m
45
45
-
45
45
Acc' Body
Kg.m
60
60
60
60
60
Acc' Cover
Kg.m
45
45
45
45
45
Divide
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8.VALVE ADJUSTER CONTROL
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Function of adjuster controlling the amount of hydraulic oil makes numbers of blows ·
Structure for adjusting the amount of hydraulic oil makes numbers of blows and impact force change through the increase and decrease of the amount of hydraulic oil of return hydraulic circuit passed to oil tank.
·
When hydraulic oil is passed much, numbers of blows go up, impact force goes down. When hydraulic quantity is passed less, numbers of blows go down, impact force goes up.
◆ Used tools and direction when to handle adjuster. Description Used tools
Clock wise
Adjuster Adjuster Nut Impact force Numbers of blows
4750
5250
6250
8250
9250
S10
S12
S8
S12
S12
S26
S32
S26
S32
S32
Up
Up
Up
Up
Up
Down
Down
Down
Down
Down
Maverick Hammers - U.S.A.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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9.TOOL
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 90
Replacement of the tool
1) Remove the stop pin and the Tool pin with a 330mm-long steel bar. When reassembling, align the groove in the Tool and the Tool pin hole and insert the Tool pins.
2) Reverse disassembly procedures to install a replacement Tool. Before installing a new Tool, check each part for wear, breakage, scores, etc. Remove burrs and swellings on each Tool pin, apply a coat of grease to the movable areas of the Tool pin and the Tool and finally install the Tool. Excessively deformed the Tool pins will make replacement of the Tool difficult. The Tool pins must be checked every 100 to 150 hours of operation. * If the replacement Tool is not a genuine part, we do not guarantee the performance of other parts of the Hammer.
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Maverick Hammers - U.S.A. How to use tools properly
The purpose of this guide to enable you to advise your customer as to the correct application of BH Demolition Tools and assist you to resolve complaints immediately they occur. When a tool has apparently failed to give satisfactory service life, a visual inspection often quickly resolves the cause and saves transport costs and frustration when warranty is rejected.
How a Demolition Tool Hammers Rock and Concrete When the hammer piston strikes the top of a demolition tool, it sends a compressive stress wave down to the working end of the tool. Provided the demolition tool is in contact with the rock or concrete which requires breaking, it is this compressive stress wave which fractures the rock. Immediately following the compressive stress wave, a tensile stress wave is formed due to the hammer piston lifting from the top of the demolition tool. This cycle of compressive and tensile stresses flowing down the tool of repeated for each hammer blow. Obviously, anything that interferes with the 'strength' if the compressive stress wave during service, for example 'free running' or bending of the demolition tool due to leverage, will result in loss of Hammer efficiency of up to 80% and possible fatigue failure of the tool itself.
Cause and Effect of Fatigue The continuous cycle of compressive and tensile stresses in the demolition tool, even under correct operating conditions, create fatigue stress in the tool which can lead to the fatigue of a demolition tool before it is worn out. Again, anything which interferes with the cycle of compressive and tensile stresses will also increase the level of fatigue stresses will also increase the level of fatigue stress being applied to the demolition tool and thus increase the risk of early fatigue failure of the tool.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 92
Maverick Hammers - U.S.A. How to use tools properly
1. The main cause of increased fatigue stress in a demolition tool is any form of side pressure during service which creates bending. Thus utilizing the tool as a lever, using the incorrect driving angle or attempting to break ground using the pull of the machine are all detrimental to the life of a demolition tool and should be avoided. (see Pic1)
PIC. 1 2.
PIC. 2
Other causes of increased fatigue stress in a demolition tool include.
a) 'Free running' In general this is any situation where the hammer piston strikes the top of the demolition tool, but the working end is not in proper contact with the rock or concrete to be broken. This includes jobs where the tool slides off the work and also when breakthrough of thin concrete slabs or boulders occurs. b) Cold Low temperature causes a demolition tool to be more susceptible to fatigue failure. Tools should be warmed before use. c) Mechanical and thermal damage Any form of damage to the surface of surface of a demolition tool renders it more liable to suffer fatigue failure. Thus all care must be exercised to prevent accidental gouging, or contact welding ('galling' or 'pick-up') due to contact between the tool and chuck bushing through the lack of lubrication or excessive leverage (see Pic2)
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 93
Maverick Hammers U S A How to use tools properly
d) Lubrication Care must be taken to avoid metal to metal contact that, as a result of galling or pick-up, could cause deep damage marks which, in turn, lead to the formation of fatigue cracks and eventual failure of the demolition tool. Ensure that the shank of the demolition tool is well lubricated before locating in the machine. Molybdenum bisulphide grease is recommended for this application at three hourly intervals or as per manufactures instruction. e) Corrosion A rusty demolition tool is more likely to suffer fatigue failure, thus keep tools well greased and sheltered from the weather when not in use.
PIC. 3
Demolition Tool Fatigue Failure A demolition tool fatigue failure will generally occur approximately 4" (100mm) either side of the chuck front face (see Pic3) Another slightly less common failure area can fall approximately8(200mm) from the working end, subject to nature of use. The fracture face itself will normally exhibit a semi-circular polished area with the remainder being of a rougher appearance (see Pic4) PIC. 4
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. How to use tools properly
The polished semi-circular area in pic4 is the fatigue area and generally starts from a damage mark or other stress raiser no the outside of the demolition tool and spreads inwards. The fatigue area slowly widens until the stresses being applied to the demolition tool cause sudden failure of the remaining section. Generally, the size of the fatigue area indicates the level of stress applied to the tool, i.e. the smaller the fatigue area, the higher the stress level, although it must be borne in mind that once initiation of a fatigue crack has taken place, if requires a lower stress level to cause it to grow.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 95
10.HOW TO CHARGE N22 GAS
Maverick Hammers - U.S.A.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 96
Back-head gas charging
① N2 gas cylinder ④ hose
② Bomb adaptor nut
③ Bomb adaptor
⑤ Gas charging kit
* Inspection of N 2 gas in the back-head 1) Make sure that the cap and the valve of the gas charging kit(⑤ ) are fully tightened. Screw the gas charging kit(⑤ ) into the charging valve of the back-head after removing the plug. 2) At this time the handle must be short to prevent the gas from coming out. 3) Push the handle into the charging valve fully, so the gas pressure inside the back-head is indicated on the pressure gauge. 4) If the gas pressure is normal, unscrew the gas charging kit after discharging gas inside the gas charging kit. Reinsert the plug to the Hammer. 5) If the gas pressure is higher or lower, charge it as described below.
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 97
Back-head gas charging
1) Connect the charging hose(④ ) to N 2 gas cylinder(① ) after screwing the bomb adapter(④) onto adapter nut(② ) and installing than to the N 2 gas cylinder. 2) Connect the gas charging kit(⑤ ) to the charging hose(④ ) after unscrewing the cap on the gas charging kit. 3) Install the gas charging kit(⑤ ) to the charging valve of the Back-Head. At this time the handle of the gas charging kit must be up position to prevent the gas from coming out. 4) Push the handle of the gas charging kit fully and turn the handle of the N 2- gas cylinder counter clockwise gradually to charge the Back-Head. 5) When the gas pressure exceeds 10% higher then the specified pressure, close the N 2 gas cylinder by turning the handle clockwise. 6) Leave the handle of gas charging kit up. generated pressure makes, it return back to original position naturally. 7) Remove the charging hose(④ ) from the N 2 gas cylinder(① ) and the gas charging kit (⑤ ), and the screw the cap onto the gas charging kit. 8) Push the handle of the gas charging kit fully, and the gas pressure inside the back-head is indicated on the pressure gauge. When the pressure is higher, discharge a small amount of gas from the back-head repeatedly opening and closing the valve and then gas pressure falls to the specified pressure. 9) When the gas pressure reaches to the specified pressure, close the valve and release the handle. 10) Open the valve completely and discharge gas inside the gas charging kit. Remove the gas charging kit from the charging valve of the Back-Head and install the plug to the charging valve.
! WARNING ■ CHARGING GAS PRESSURE CHANGES ACCORDING TO THE TOOL CONDITION. LAY DOWN THE HAMMER AND LET THE TOOL EXTEND FULLY. ■ STAY CLEAR OF THE TOOL WHILE CHARGING THE HAMMER WITH GAS. THE TOOL MAY BE IMPACTED BY THE PISTON AND FORCED OUT ABRUPTLY. ■ WHEN THE THROUGH BOLTS ARE CHANGED THE N2 GAS MUST BE DISCHARGED WITH THE BACK HEAD, AS IT IS HIGHLY PRESSURIZED. ■ USE NITROGEN GAS ONLY. ■ SEE "CONVERSION TABLE FOR CHARGING N2 GAS PRESSURE TO THE BACK HEAD"
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Accumulator gas charging
① N2-Gas cylinder ② Bombe adaptor nut ③ Bombe adaptor ④ Hose ⑤ Gas charging kit ⑥ O-ring ⑦ O-ring-hex bushing ⑧ O-ring ⑨ O-ring plug ⑩ O-ring ⑪ O-ring cap ⑫ Accumulator charging valve ⑬ O-ring
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Accumulator gas charging
1) Connect the charging hose(④ ) to the N 2 -Gas cylinder(① ) after screwing the bomb adapter(③ ) on to the adapter, the nut(② ) and installing to the N 2 -Gas cylinder. 2) Connect the gas charging kit(⑤ ) to the charging hose(④ ) after unscrewing the cap on the gas charging kit. 3) Remove the cap(⑪ ) from the accumulator and tighten the charging valve(⑫ ) fully. 4) Check if the o-rings (⑥ )(⑧ ) are installed to the bushing(⑦ ). Remove the plug(⑨ ) and screw the bushing. 5) Loosen the accumulator charging valve(⑫ ) after checking if the bushing(⑦ ) is installed to the gas charging kit. 6) Turn the handle of the N 2 -Gas cylinder counter clockwise slowly to charge gas. 7) Charge gas in accordance with the conversion table for charging N 2 -Gas pressure to the accumulator. 8) Turn the handle of the N 2 -Gas cylinder clockwise to close the cock. 9) Close the accumulator charging valve. 10) Loosen the valve of the gas charging kit to discharge the N 2 -Gas remaining in the charging hose. 11) Remove the charging hose, the gas charging kit and the bushing and tighten the plug(⑨ ) and cap(⑪ ).
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Caution for gas charging
■
Be sure to use the gas charging kit for charging the N 2 gas. If charging gas leaks directly from the cylinder, the diaphragm may be broken off.
■
If charging for handling N 2 gas to only the accumulator, make sure that the accumulator body and the cover are tightened fully.
1) Make sure the cap and the valve of the gas charging kit(⑤ ) are fully tightened. 2) Remove the cap(⑪ ) from the accumulator and tighten the charging valve(⑫ ) fully. 3) Check if the O-rings(⑥ )(⑧ ) are installed to the bushing(⑦ ). Remove the plug(⑨ ) and the screw in the bushing. 4) Install the bushing(⑦ ) to the gas charging kit(⑤ ). 5) Loosen the charging valve(⑫ ) gradually. The charging pressure is indicated on the pressure gauge. 6) Close the valve clockwise when the gas pressure is normal. When the gas pressure is higher, repeat loosening and tightening the valve of gas charging kit. The pressure is lowered gradually. 7) Loosen the valve of the gas charging kit to discharge the N 2- gas in the gas charging kit(⑤ ) 8) Remove the gas charging kit(⑤ ) and tighten the plug(⑨ ) and the cap(⑪ ).
! WARNING ■
USE SPECIAL CARE TO HANDLE AND STORE THE N2-GAS CYLINDER AS IT IS A HIGHLY PRESSURIZED CONTAINER.
■
USE NITROGEN GAS ONLY.
■
STANDARD ACCUMULATOR GAS PRESSURE 55kg/cm2/780PSI AT 20 /68
AMBIENT TEMPERATURE. DO NOT OVER
PRESSURIZE THE ACCUMULATOR. ■
SEE "CONVERSION TABLE FOR CHARGING N2-GAS PRESSURE TO THE ACCUMULATOR".
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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11.CHECK LIST FOR MAINTENANCE
Maverick Hammers - U.S.A.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 102
Maintenance Checklist
Check items
Check points
- Looseness, missing and damage to the bolts and the nuts
- Through bolts - Bracket mounting bolts - Accumulator bolts
- Looseness of the hose fittings, visible damage to the hoses and oil leakage
- Hydraulic pipes for the Hammer - Oil hoses
- Abnormal oil leakage
- connections of the Back-Head and the cylinder - Clearance between the front head & the Tool
- Abnormal wear and cracks on the Tool
- Tool
- Greasing
-Grease at start and every 2 or 3 hours using the head grease pump -Pumping : 5~10 times
- Hydraulic oil level and contamination
- Conditions of the hydraulic oil
- Missing the rubber plugs and the snap rings
- Rubber plugs - Snap rings
- Auto-Greasing kit, looseness, missing and damage
- G-adapter
- Air supply Kit, looseness, missing and damage
- W-adapter
- The Back-Head gas and the accumulator gas
- Filling the Back-Head gas and the Accumulator
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A.
12.GUIDE FOR TROUBLE SHOOTING
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 104
Maverick Hammers - U.S.A. General guide for the trouble-shooting TROUBLE 1. Hammer fails to hammer (1) Sufficient high pressure oil does not flow to Hammer inlet. (2) Sufficient high pressure oil flows to Hammer inlet.
CAUSE
REMEDY
(a) Defective hose or pipes. Clogged or
(a) Check, clean and repair piping or replace with new ones.
damaged piping (b) Defective control valve and related
(b) Check and repair Valve and its
parts. Missing or damaged tie Tool or
related parts or replace with new
control cable
ones.
(c) Insufficient hydraulic oil
(c) Refill the oil tank.
(d) Internal Hammer defects
(d) Consult with our service station.
2. Hammer hammers with hammering force reduced.
(a) Defective hose or pipes. Clogged or damaged piping
(a) Check, clean and repair piping or replace with new ones.
(1) Sufficient high pressure oil does (b) Defective control valve and related
(b) Check control Valve and related
parts. Deformed pedal. Deformed
parts or replace with new ones.
not flow to Hammer inlet. (2) Sufficient high pressure oil flows to Hammer inlet.
control valve. Stuck control valve.
(c) Clean or replace.
Insufficient control valve stroke due to
(d) Refill.
loose screws
(e) After flushing tank, change oil
(c) Clogged filter in return line of base machine tank
entirely (f) Ask service station for base machine
(d) Insufficient hydraulic oil
service.
(e) Contaminated or deteriorated hydraulic oil
(g) Consult with our service station. (h) Adjust the gas pressure referring to
(f) Defective pump
Chpt. 9,10
(g) Internal Hammer defects. Entry of contaminated
articles
(h) Decrease in N2-gas sealing pressure of Back-Head
3. Hammering force plummets
(a) Defective Back-Head. Gas leakage
(a) Ask our service station for repairs
suddenly and high pressure hose vibrates excessively during operation.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. General guide for the trouble-shooting
TROUBLE 4. Excessive oil leakage from front
CAUSE
REMEDY
(a) Worn cylinder seals
(a) Ask our service station or repairs
(a) Stuck tool
(a) Remove front parts and pull out Tool
head or Tool. 5. Piston works but does not hammering.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
and check it.
Page 106
13.WEAR LIMIT REFERENCES OF THE MAIN PARTS
Maverick Hammers - U.S.A.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 107
Wear limits of the piston
Model
L
H
350
391
1
400
391
1
500
405
1
750
418
1
1000
485
1
1500
487
1
2250
660
1
3250
679
1
4750
763
2
5250
880
2
6250
790
2
8250
966
2
9250
955
2
10,000
1,100
2
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 108
Wear limits of the tool
Model
H
L
350
252.5
200
400
317
200
500
323
200
750
327
200
1000
415
250
1500
367.5
250
2250
465
250
3250
561
300
4750
697
400
5250
763
400
6250
715
400
8250
804
400
9250
890.5
500
10,000
980
500
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 109
Wear limits of the tool bush
350
Inside diameter A as a new part ø36
Inside diameter at reject limit ø38
400
ø45
ø47
500
ø53
ø55
750
ø60
ø62
1000
ø68
ø71
1500
ø75
ø78
2250
ø85
ø89
3250
ø100
ø105
4750
ø120
ø125
5250
ø135
ø140
6250
ø140
ø145
8250
ø150
ø155
9250
ø160
ø166
10,000
ø180
ø186
Model
Maverick Hammers - U.S.A. Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 110
Wear limits of the tool and tool bush The Tool is deformed by burrs occurring after long-term use. When a Tool tip is worn out, The Tool is liable to slip. Then, sharpen the Tool tip. Grinding the Tool tip many times to sharpen the edge, but it will make the heat-treated hardened with a new Tool. If the gap between the Tool and the Tool bush becomes large, the piston will fail exactly to hit the upper part of the Tool, resulting in damage. When the gap is found to be over 9mm, replace the Tool bush together with the Tool.
Divide
Dimension Tool Bush
Model
Width of Wear Tool Dia
( mm )
350
40
40
3
400
45
45
3
500
53
53
3
750
60
60
4
1000
68
68
4
1500
75
75
4
2250
85
85
5
3250
100
100
6
4750
120
120
7
5250
135
135
8
6250
140
140
8
8250
150
150
9
9250
160
160
11
10,000
180
180
12
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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M
i kH
USA
Wear limits of the tool pin
Model
L ( øD )
H
350
ø24.4
2
400
ø24.4
2
500
ø24.4
2
750
ø30
2
1000
ø30
2
1500
ø30
2
2250
54
2
3250
60
3
4750
72
3
5250
80
3
6250
90.5
3
8250
90.5
3
9250
110
3
10,000
125
4
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A. Wear limits of the thrust bush
øA Model
L
H
ø38
12
3
ø45
ø47
14
3
500
ø53
ø55
17.5
3
750
ø60
ø62
19
3
1000
ø68
ø71
18
3
1500
ø75
ø78
19.5
3
2250
ø85
ø89
31
3
3250
ø100
ø105
27
3
4750
ø120
ø125
30
3
5250
ø135
ø140
32
3
6250
ø140
ø145
53
3
8250
ø150
ø155
40
3
9250
ø160
ø166
39
3
10,000
ø180
ø186
60
3
Inside diameter A as
Inside diameter at
a new part
reject limit
350
ø36
400
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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14.HYDRAULIC OIL
Maverick Hammers - U.S.A.
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 114
Hydraulic Oil
The Selection of the hydraulic oil determines the efficiency of the hydraulic Hammer performance. Please consult with our service station under following conditions. (a) When used in special regions where the climate is extremely cold or hot and, viscosity may be changed at different constant ambient air temperatures. (b) When recommended brands of hydraulic oil are not available. (c) When hydraulic oils supplied for the base machine differ from the recommended one.
Maker Summer
Hydraulic Oil
Grease
Viscosity Grade
NLGI NO.2
SAE68
Winter
SAE46
Shell
Shell Tellus T68
Shell Tellus T46
Esso
Nuto H68
Nuto H46
Alvania Grease2
Mobil
Mobil DTE16
Mobil DTE15
Beacon Q2
Gulf
Harmony 68
Harmony 46
Mobil Grease Special
* Oil Contamination
Contaminated oil results in malfunctions of the Hammer as well as the base machine and causes damage to the parts. Pay special attention to oil contamination. Contaminated oil should be changed without delay. When changing oil, thoroughly wash the oil tank, the cylinder and the pipes. Cleaning or replacing the oil filter also requires check for oil contamination.
â&#x2013; Replacement of the filter : after first 50 hours and every 100 hours â&#x2013; Replacement of the hydraulic oil : every 500 hours
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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Maverick Hammers - U.S.A.
15.OPTIONS
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 116
Maverick Hammers - U.S.A. Auto grease system
AUTO GREASE LINE
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 117
Maverick Hammers - U.S.A. Under water system Circuit of Under Water System
Recommended capacity of Air Compressor
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
Page 118
Maverick Hammers - U.S.A. Anti dust system ( 1000 ~ 10,000 )
- Piston up -
- Piston impact -
* Anti dust system - the air check valve Discharges Dust Through Tool
Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual
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