FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
OPERATING PROCEDURES WILL CAUSE
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
OPERATING PROCEDURES WILL CAUSE
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
OPERATING PROCEDURES WILL CAUSE
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
MODEL DH205
(Anti
-
Vibration Model)
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
OPERATING PROCEDURES WILL CAUSE
DAMAGES OF THE MACHINE.
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
MODEL DH205
Vibration Model)
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
CAUTION
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
DAMAGES OF THE MACHINE.
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
MODEL DH205
Vibration Model)
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
CAUTION
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
DAMAGES OF THE MACHINE.
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
DAMAGES OF THE MACHINE.
2
FOREWORD
This manual is an important part of your equipment. It provides
rules and guidelines which will help you use this machine safely and
effectively. You
MUST
familiarize yourself with the functions and
operations by reading the manual thoroughly before you begin using
this machine. For your safety, it is especially important that you
read and observe all precautions in this manual and labels on the
machine. The precautions
MUST
be followed strictly at all times
when performing operation and
maintenance
. * Fail to follow the
guidelines and safety alerts in the manuals and on the machine, or
use this machine in alternative ways from the manuals may result in
system failure or serious personal injury.
Keep this manual with the equipment or in an easily accessible place
in all times for future reference. Make sure all personnel involved in
working on this machine can consult it periodically. In case this
manual should be lost or damaged, immediately contact us or your
dealer to purchase a new copy.
We recommend you always use Maruzen genuine components and
parts. Replacing components and parts from other sources may cause
damages to this machine and endanger operators.
MARUZEN KOGYO CO., LTD.
155
-
8 NAGABUSE, MISHIMA
-
SHI,
SHIZUOKA
-
KEN, 411
-
0824, JAPAN
3
CONTENTS
Safety Information
.............................................................
4
8
Safety Alert Classifications
..........................................
4
Safety Alerts
..................................................................
5
8
Introductions
......................................................................
9
Specifications & Descriptions
............................................
10
Precaution Labels and Positions
.......................................
11
Inspection before Each Operation
.....................................
12
Operation
............................................................................
13
14
Guidelines
...........................................................................
15
16
Installation of 5kg Weight
.................................................
16
Inspections
..........................................................................
17
Tools & Applications
...........................................................
17
Troubleshooting
..................................................................
1
Exploded View
..................................................................
21
Parts List
............................................................................
22
24
EC Declaration of Conformity
...........................................
25
4
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions
and labels
are given in this manual and affixed to the machine to give
explanations of situations involving potential hazards and of the
methods of avoiding such situations.
SAFETY ALERT CLAS
S
IFICATIONS
The following safety alert symbols are used to inf
orm you that there is
a potential hazardous situation that may lead to personal injury or
damage.
In this manual and on machines labels, the following
safety
alert
symbol are used to express the potential level of hazard.
** Safety alert symbols are to emphasize all operation which, if not
strictly followed, could result in a life-threatening situation, bodily
injury or dam
age to equipment.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, could result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate
injury.
5
DO NOT OPERATE THE MACHINE UNLESS THE FOLLOWING SAFETY
INSTRUCTIONS HAVE BEEN THOROUGHLY READ AND UNDERSTOOD!
WARNING
SAFETY ALERTS
Read and understand operating manual
before operating.
WARNING
Be
Cautious About
High Pressure Hydraulic Oil
There is a risk of sudden breakage of hydraulic hoses
which causes the oil inside belch out.
1.
Relief the pressure inside before disconnecting
hoses.
2.
DO NOT inspect oil leakage with your bare
hands. Because oil leakage is very often not
noticeable
, ALWAYS use cardboard or wood
pieces to assist your inspection
WARNING
Be Cautious About High Pressure Gas
1.
High pressure nitrogen gas was installed inside
accumulator.
2.
DO NOT
un
-tighten the cap from the top of the
breaker.
* Failure to observe this precaution can result personal
injuries.
6
Before operating the equipment, be
sure to wear personal protective
equipments such as follows:
1.
Helmet
2.
Protective goggles
3.
Protective boots
4.
Safety gloves
5.
Hearing Protection
6.
Mask
WARNING
Be Cautious About High Heat
1.
Following by rapid raise of the oil temperature,
the temperature of the machine goes up while
and after the operation. DO NOT touch the
machine with your bare hands.
2.
The temperature of tools will also raise while or
after the operating. BE SURE that you
always
wear protective equipments while handling tools.
*Failure to observe this precaution can result getting
burned.
WARNING
* Failure to observe this precaution can result
serious
personally
injuries.
7
Do not operate the equipment if you are
or if your
1.
taking medication, feeling
drowsy
, feeling unwell or feeling
tired.
2.
under the influence of drugs or alcohol.
3.
hands, feet, lower back or other parts of
your
body hurt or
being injured.
* Failure to observe this precaution can result serious injury or
ev
en death.
WARNING
CAUTION
When lending someone the equipment
Make sure the safety instructions have been
thoroughly
read and fully understood by the person who is going to use
the equipment.
WARNING
Avoid Blank Hammering
Operating the equipment horizontally may cause the
chisel
s sudden flying out.
Failure to observe this precaution can result damage to the
breaker.
8
WARNING
Never operate the breaker when
bystanders are in the work area
1.
Do not operate the breaker if any people are within
the area where flying debris or movement of the
breaker may injure them.
2. For preventing flying debris, make sure protection
fences are being set up.
Failure to observe this precaution can result pers
onal
injury.
9
INTRODUCTION
1.
This hydraulic rock drill is designed to be used for the following
purposes.
(1)
Equipped with drilling rod for drilling holes on rocks, concrete
and etc.
(2)
Equipped with grooved moil point for breaking rocks, concrete
and etc.
2.
DO NOT
operate this rock drill on the following situations:
(1)
Drench part of the rock drill or whole rock drill into water or
seawater.
(2)
Connect with power source which its oil flow and pressure exceeds
the rock drill
s
allowable range.
(3)
Operating with oil temperature below 10
or over 90
.
(4)
Use shank which its size is different from prescribed.
(5)
Attach to other construction machinery.
(6)
Use the equipment for purposes other than stated in this manual.
(7)
Use parts other than Maru
zen
genuine
ones.
(8)
Connect with extension hose its length exceeds 1/2 in x
2
0m.
10
11
SPECIFICATIONS
& DESCRIPTIONS
Overall Dimensions L694
x W
410
x T
110
Overall Weight
20.0
Kg (Tool excluded)
Working Pressure
7.8
11
.8
MPa
Max. Pressure 20.6 MPa
Oil Flow
20 25
L/min
Blow Per Minute
1000
-
1350
bpm
Vibration Level(ISO08662
-5)
Z=
4.6
m/s²
(With 5kg Counter Weight added) Z = 3.7
m/s²
Sound Power (200/14/EC)
-
Measured Sound Power Level
Lwa
=
102
dB
(A)
-
Guaranteed Sound Power Level
Lwa =10
3
dB
Shank Size
7/8
x
4-
1/4
(22x108mm) hex
Coupling 3/8 in
couplers
Extension Hose
1/2
in x
2
0m
(max)
Handle
Grip
Accumulator
Control Lever
Safety Lock Lever
Air Cleaner
Drill Stay
Drill Rod
Gear Motor
Hoses
Coupler (Male)
Coupler (Female)
Adjusting Dial Know
Recommended Hydraulic Oil ISO VG32 or equivalent
PRECAUTION LABELS AND POSITIONS
Recommended Hydraulic Oil ISO VG32 or equivalent
PRECAUTION LABELS AND POSITIONS
Recommended Hydraulic Oil ISO VG32 or equivalent
PRECAUTION LABELS AND POSITIONS
Recommended Hydraulic Oil ISO VG32 or equivalent
PRECAUTION LABELS AND POSITIONS
Precaution Labels are to remind you to be extra
cautious for
important that all the safety precaution labels are
legible in all time. Replace new once when they are
illegible.
Order your precaution labels from your nearest
Maruzen dealer.
Code
MPL1Z074A0
MPL1E075A1
MPL2Z001A1
MPL2Z002A1
MPL2Z003A1
Precaution Labels are to remind you to be extra
cautious for
potential
important that all the safety precaution labels are
legible in all time. Replace newonce when they are
illegible.
Order your precaution labels from your nearest
Maruzen dealer.
Code
MPL1Z074A0
MPL1E075A1
MPL2Z001A1
MPL2Z002A1
MPL2Z003A1
Precaution Labels are to remind you to be extra
hazards. It is extremely
important that all the safety precaution labels are
legible in all time. Replace new once when they are
Order your precaution labels from your nearest
Description
Label BY (WARNING)
Label BZ (WARNING)
CE Sticker (in French)
CE Sticker (in English)
CE Sticker (in Italian)
12
Precaution Labels are to remind you to be extra
hazards. It is extremely
important that all the safety precaution labels are
legible in all time. Replace new once when they are
Order your precaution labels from your nearest
Description
Label BY (WARNING)
Label BZ (WARNING)
CE Sticker (in French)
CE Sticker (in English)
CE Sticker (in Italian)
13
INSPECTIONS BEFORE EACH OPERATION
For the purpose of keeping the breaker in good
condition, make sure the following inspection items
are done each time before using. (Refer the drawing
on the right)
Inspection Items
Countermeasures
1. L
oose
nut
Tighten the loosen nut
2. Loose
handle attachment
Tighten handle attachment
3. Loose hose attachment
Tighten hose attachment
4. Cracks on handle grips
Replace new one when cracks are found
5. Wears found on
Drill Stay
Refer to the drawing on the right
MPL2Z00
5
A0
Sound Power Level Sticker (10
3)
14
6.
Wear of bit
Replace new one
7. Oil leakage
Ask your dealer for repair and service
8. Cracks on control lever
Ask your dealer
for repair and service
9. Damage of hoses
Replace new one especially when the
damage of wires found
An
air cleaner is equipped to prevent dust
being sucked into
built
in compressor. Ref
er to the drawing below
for air cleaner cleaning.
Remove the cleaner case and air
(blow) clean the
Element
and
Sponge
every day. Fail to do
the cleaning can hasten the ware of
compressor,
piston and etc.
Hook
Cleaner Element
Cleaner Sponge
Cleaner Cover
15
OPERATION
1.
Before Star
t
(1)
Open the drill stay and insert the rod.
(2)
Close the drill stay. Make sure the rod (or other tools) is
firmly locked.
(3)
Make sure couplers are clean. (No dust, mud or other
foreigner substance attach to them) Connect rock drill with
power source with extension hoses.
(4)
Start the power source. Allow hydraulic oil to flow into rock
drill. (Switch
the valve and etc)
2.
Start drilling
(5)
Place the end of
the rod
on the place where you intend
to drill,
pressure down the rock drill gently, grip the control lever and
start drilling.
(6)
For preventing rock driller dancing around while operating,
let the end of the rod closed to one of your feet and drill till
th
e rock drill can be stably operated.
(7)
Adjust
the
rotation
speed according to the type of the rock
Graduation
Rotation Speed
Applications
1
100
150rpm
Hard Rock
2
200
250rpm
Medium to Hard Rock
3
350
400rpm
Soft Rock
Adjust the scale mark to
the line here
Knob for adjusting speed
16
3.
Breaking
(8)
Fluted moil point allows the escape of the air
(9)
Open the drill stay and insert moil point.
(10)
Close the drill stay. Make sure the moil point has been
fastened firmly.
(11)
Adjust
the knob to
O
po
sition
4.
After the operation
(12)
After the operation, stop the power source.
(13)
Use the moil point to push up the piston to the end.
(14)
Detach the connection hoses.
(15)
Make sure all the couplers on standard hoses (attached to
rock drill) and connection hoses are attached to each other to
prevent dirt and etc entering.
(16)
Open the drill stay
, remove the tool (moil point)
(17)
Clean all the dirt, mud and etc on the rock drill.
17
GUIDELINES
1.
While using power source other than Maruzen power units,
consult with Maruzen or your dealers before the operation.
2.
Always use Maruzen genuine t
ools.
Use other than Maruzen
genuine tools may cause breakage of tools which may lead to the
damage of rock drill
and personal injury.
3.
Make sure the power source is OFF when connecting the breaker
to the power source.
4.
Pay attention to the follow
ings while operating the rock drill
.
(1)
Be cautious for not being injured by the front of the to
ol.
(2)
Be cautious for not being tripped or fallen by the extension
hoses.
(3)
Make sure there are no
obstacle
s at jobsite. Clear the work
area of objects which might cause operator to trip or fall.
(Be
cautious not being tripped by obstacles while operating)
(4)
While pulling out the rock drill from the broken objects, be
cautions for not being fall over.
(5)
Make sure the rock drill was placed in horizontally. Fail to
place the rock drill horizontally after operating can cause
injury by sudden falling of the breaker
.
(6)
Be cautious not to injure you
r back while lifting the rock drill
.
5.
Connect male and female couplers on the same extension hoses
together after detaching from power source and rock drill.
6.
When rock drill does not stop after releasing the control lever.
STOP the power source IMMEDIATELY.
You
MUST bring the
rock drill to Maruzen dealer
s for repairing and inspection.
7.
In case of
sudden breakage of hydraulic hose occurs and oil splash
out th
e hoses, STOP the power source IMMEDIATELY.
8.
When detach couplers, a small amount of oil may slip out. Make
sure that surrounding area does not get dirty by oil.
9.
Do not change tools (moil point and etc) while rock drill is still
connected with power source
.
10.
When connecting and disconnecting couplers, make sure dirt, dust
and other foreign substance does not enter or attach to couplers
and hoses.
11.
If the oil temperature is below 10
, warm up the power source by
running it for a while before start operating.
12.
DO NOT attach this rock drill to any other construction
machinery.
18
13.
Do not drench part of the rock dill or whole rock drill into water or
sea water.
14.
DO NOT use damaged hydraulic hoses or worn hydraulic hoses.
15.
Make sure the followings have been done before store rock drill in
long term.
(1)
Wide entire body of rock drill with wet cloth with hydraulic
oil.
(2)
Cover rock drill and store at the place without humidity.
DAILY CHECK OUT
Check before each operation
1.
Check
if there is any oil leakage from hoses or breaker itself.
2.
Check if there are any cracks or damage in tools.
PERIODICAL INSPECTION
Ask your dealer for the periodical inspections.
Inspection Items
Operating Hours
Nitrogen gas charge in accumulator
300
hours or 1 Year
Replacement of accumulator diaphragm
500 hours or 2 years
Replacement of Valve Rod O ring
500 hours or 2 years
Replacement of U
-
cup packing
500 hours or 2 years
Replacement of each O ring
M
ore than 3 years
*
Accumulator Nitrogen gas
pressure: 3.9MPa (40kgt/
)
19
Symptoms
Causes
Countermeasures
Grip the control lever but does not start
1.
Power source is off (Switch lever is
not in ON position)
2.
Selector valve is off
3.
Hoses are not
connected
4.
Couplers are not connected properly
5.
Relief valve pressure is set too low
6.
Damage of control lever
7.
Control lever is not functioning
8.
High
pressure
side and oil return
side was connected inversely
1.
Start the power source (Turn the
switch lever to
On position)
2.
Allow hydraulic to flow into rock
drill
3.
Connect hoses
4.
Check out if all the couplers have
been connected properly
5.
Adjust pressure to the range of 11
.7
20.6MPa
*
6. Replace a new control lever *
7. Disassemble rock drill, clean and
remove dirt and dust between
control lever and valve body *
8. C
onnected
high pressure hoses
to
the upper side of
rock drill
Breaking but rod does not rotate
1.
Dial knob is on
0
position
2.
Damage of the key in gear motor
3.
Foreigner
substance
inside gear
motor
1.
Dial the knob to desire rotation
speed 1
3
2.
Disassemble and replace the gear
motor
3.
Disassemble and replace the gear
motor
Functioning but weak hammering or low
hammering speed
1.
Low rate of oil flow from power
source
2.
Not enough hydraulic oil
3.
Pressure in relief valve in power
source is set too low
4.
Turn the engine rotation rate up and
increase the rate of oil flow (Adjust
oil flow to the necessary rate)
5.
Refill hydraulic oil
Adjust pressure to the range of 140
210kgf/
(13.7
20.6MPa) *
TROUBLE SHOOTING
20
Hammering in normal
speed, but week
hammering
1.
Low
rate of
accumulator gas
pressure
2.
Damage of accumulator diaphragm
3.
Oil temperature is abnormally high
4. Back pressure too high
1.
Refill Nitrogen gas
40kgf/
(3.9MPa) *
2.
Replace diaphragm *
3.
Inspect hydraulic power unit, clean
radiator and fan
4.
Use wider hydraulic hoses.
Increase the oil temperature to
lower the back pressure
Poor in dust discharge
1.
Clog of air cleaner element
2.
Foreigner
substance
inside lead
valve
3.
Damage of lead valve
4.
Damage of piston ring
5.
Damage of bush
1. Turn the engine rotation rate down
to decrease the rate of oil flow
(Adjust oil flow to the right range)
2. Disassemble and clean
3. Replace new one *
4.
Replace new one *
5.
Replace new one *
Oil leakage from control lever
1. Damage, wear or harden of
O ring
1. Replace O ring *
Dust mixed with oil
1.
Damage of U cup packing
2.
Damage of U cup packing due to the
damage(scars) of piston
1.
Replace new one *
2.
Replace new U cup packing. Remove
the scars on piston by oil stone
Abnormally high rate of hammering
(bp
m) and strong back action
1.
Overflow of hydraulic oil
1. Adjust the oil flow to the range of 20
25L/min
Oil leakage of gear case
1. Damage of internal shaft O Ring
2.
Damage of O ring in motor block
1. Replace new one
*
2. Replace new one *
Air
blow for discharge dust does not
work
1.
Damage of piston
2.
Damage of lead valve
3.
Damage of bush
1.
Replace new one *
2.
Replace new one *
3.
Replace new one *
While in Breaking mode, air can
t escape
1.
Fail to use grooved
moil point
1.
Use only grooved moil point
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