F1-F5 Adj PDF

Section IV -- Page # 1
SECTION IV

MAINTENANCE & ADJUSTMENTS


DAILY BREAKER INSPECTION
F1 through F5 Hammers

WARNING: Any maintenance should be done in a safe, obstruction-
free environment.

The following is a list of items should be inspected on a daily basis:

A) Item: Loose, missing or damaged nuts and bolts
Location: Accumulator cover mounting bolts
Top cover bolts and nuts 1
Retainer and stop pins 2
Through bolts and nuts
Frame cross bolts and nuts 7
Remedy: Re-torque according to the torque specification page
in this manual.

B) Item: Missing rubber plugs, GPF and screw plugs
Location: Fronthead, Grease port 2,6
Remedy: Replace


C) Item: Loose or damaged hydraulic lines
Location: Pressure and return lines for the breaker 3
Remedy: Tighten any loose fittings
Replace any damaged hoses or piping

D) Item: Abnormal oil leakage at lower end of breaker 4
Location: Connection between the backhead, cylinder and front head
Clearance between the working steel and front cover
Remedy: Breaker should be re-sealed
Contact your dealer

E) Item: Abnormal wear on the working steel
Location: Working steel 5
Remedy: All burrs should be removed with a grinder
If the point is worn, reshape with a grinder
(Refer to the WORKING STEEL" section of this manual)

F) Item: Grease
Location: Front head 6
Remedy: Grease at the start and every 2 to 3 hours of operation
5 to 10 pumps from a hand grease gun is recommended with the
working steel pushed up into the breaker

G) Item: Fluid level and contamination of hydraulic oil
Location: Oil Reservoir, Filters
Remedy: If fluid level is low, fill per manufacturer's specifications
To inspect for contamination, refer to the "HYDRAULIC FLUIDS and
GREASES" section of this manual.

To maintain the optimum performance from the breaker, it is recommended that a
complete inspection and maintenance be done periodically.


HYDRAULIC FLUIDS and GREASES
F1 through F5 Hammers

The life-blood of the breaker is the hydraulic oil. In order to maintain peak
performance from the breaker, it is essential to use the correct oil as well as maintain a
clean hydraulic system.

SELECTION OF HYDRAULIC OIL
To select the proper oil, refer to the following table:
ISO VG 68 ISO VG 46
MANUFACTURER ( HOT WEATHER ) (COLD WEATHER) ( EXTREME COLD )
SHELL TELLUS OIL 56 TELLUS OIL 46
ESSO NUTO H68 NUTO H46
MOBIL DTE 26 DTE 25 DTE 13
** NOTE: IF A PHOSPHATE ESTHER FLUID IS USED, SPECIAL SEALS ARE
REQUIRED. CONSULT YOUR FURUKAWA ROCK DRILL USA REPRESENTATIVE.

HYDRAULIC OIL CONTAMINATION
Oil contamination can result in malfunctions and unsatisfactory performance of
both the hydraulic breaker and the base machine. Special attention must be paid to
the hydraulic system. The hydraulic system of the base machine may become
contaminated faster when using a breaker than when using a bucket or other
attachment. The following guidelines should be followed when using a hydraulic
breaker:
When installing the breaker onto a machine for the first time, drain the hydraulic
system of the base machine completely. Flush the reservoir, cylinders and piping as
thoroughly as possible. Replace the main line oil filter cartridge. Add new hydraulic
oil. If the base machine is brand new, this step may be omitted.
The main return filter element should be replaced after the first 50 hours of
operation and every 125 hours thereafter.
Change the hydraulic oil after the first 250 hours of operation and every 600 hours
thereafter or sooner in accordance with the carrier manufacturers specifications.
Normal oil temperature should be maintained between 100F and 140F during
hammer operation.

CAUTION: Do not operate the hydraulic breaker if the oil temperature
exceeds 176F. Operation at such temperatures would substantially
shorten the life of the breaker.


Oil contamination should be kept to ANAS NO.9 class.

Field determination of contamination is as follows:

Place a sample of the base machine's hydraulic oil in a transparent container. Also
place a sample of unused oil in another transparent container. Compare the two
containers. If there is a visual difference in the color, the base machine's oil is
presumed to be contaminated.

GREASE

Furukawa Rock Drill USA's small F Series hydraulic breakers are equipped with
one (1) grease fitting. This fitting is located on the front bushing, down by the working
steel (refer to the illustration below). Lack of lubrication can cause failure of the
working steel, piston or shorten the life of the seals. An NLGI NO.2 grease is
recommended. The following is a list of the recommended greases:

SHELL ALVANIA EP2
ESSO LITHTAN EP2
MOBIL MOBILPLEX 48

The fronthead should be lubricated every 2 - 3 hours of operation. Grease more
frequently, if needed, but do not over-load the tool with grease.

When greasing the hammer, hold it in an upright, vertical, position, being sure that
the working steel is fully engaged into the chuck.

Avoid getting rock or cement chips into the fronthead when replacing working
steels. Particles which may have adhered to the grease can cause scratches and
scaring inside the hammer.

Revised April, 2010
Section V -- Page 1

SECTION V

TORQUE SPECIFICATIONS
& BREAKER WEAR LIMITS

Section V -- Page 2

F1 ~ F5 Hammers

Note: Some external box, plates, or weldments have been removed for clarity.
This drawing is representative of a number of models and might
not match your hammer.

As a general rule, all bolts should be torqued in sets, so that
the load is divided equally among any bolts that function as a
group. Torques listed refer to lubricated threads. Apply anti-sieze
compound to all threads, nuts, and washers prior to assembly. All
bolts in a group should first be loosened, and then re-tightened in
stages, alternately bringing opposing bolts up to the same torque
level, until all bolts in the group share the load equally. Continue in
the same way, bringing all bolts in that group up to the final torque
level specified.

Revised April, 2010
Section V -- Page 3

F1 Series Hammers

1) Through Bolt Hex Nut Torque: 180 ft-lbs. (25 kg-m)
Every 50 hours of operation

2) Accumulator Cover Bolts Torque: 180 ft-lbs. (25 kg-m)

3) Accumulator Plug Torque: 60 ft-lbs. (8 kg-m)

4) Accumulator Cap Torque: 60 ft-lbs. (8 kg-m)

5) Cross Bolts (Upper & Lower) Torque: 130 ft-lbs. (18 kg-m)

Section V -- Page 4

F2 Series Hammers





Top Cap Bolts (Qt & FSP Models) Torque: 95 ft-lbs. (13 kg-m)

Revised April, 2010
Section V -- Page 5

F3 Series Hammers






Section V -- Page 6

F4 Series Hammers







Revised April, 2010
Section V -- Page 7

F5 Series Hammers







Section V -- Page 38

WEAR LIMIT DIMENSIONS FOR REPLACEMENT PARTS
Front bushing (F1 ~ F9)

Model
Bore(A) of new
Wear limit of bore
Bore(A) of new
Wear limit of bore
US (Inches) Metric (mm)
F1

F2
1.772 1.850
45 47
F3
2.047 2.126
52 54
F4
2.362 2.441
60 62
F5
2.677 2.835
68 72
F6
2.953 3.110
75 79
F9
3.543 3.701
90 94

Front cover (F12 ~ F70)

Model
Bore(A) of new Wear limit of bore Bore(A) of new
Wear limit of bore
F12
4.134 4.370
105 111
F19
4.724 4.961
120 126
F22
5.315 5.551
135 141
F27
5.512 5.748
140 146
F35
5.906 6.220
150 158
F45
6.496 6.811
165 173
F70
7.086 7.401
180 188

Measurement at a location
0.38" (10 mm) from the edge.
Measurement at a location
0.38" (10 mm) from the edge.

Piston (F1~ F5)

Model
Dimension(A)
of new part
Wear limit
dimension (B)
Dimension(A)
of new part
Wear limit
dimension (B)
F1 1.378 1.339 35 34
F2 1.378 1.339 35 34
F3 1.772 1.732 45 44
F4 1.969 1.929 50 49
F5 2.087 2.047 53 52

Piston (F6 ~ F70)

Model
Dimension(A)
of new part
Wear limit
dimension (B)
Dimension(A)
of new part
Wear limit
dimension (B)
F6 .591 .551 15 14
F9 .591 .551 15 14
F12 .787 .728 20 18.5
F19 .787 .728 20 18.5
F22 .984 .925 25 23.5
F27 .984 .925 25 23.5
F35 .984 .925 25 23.5
F45 1.181 1.122 30 28.5
F70 .590 .531 15 13.5

Rod Pin (F1 ~ F9)

Model
Dimension(A)
of new part
Wear limit
dimension (B)
Dimension(A)
of new part
Wear limit
dimension (B)
F1 .787 .709 20 18
F2 .984 .906 25 23
F3 .984 .906 25 23
F4 1.181 1.102 30 28
F5 1.378 1.260 35 32
F6 1.181 1.102 30 28
F9 1.378 1.260 35 32

Rod Pin (F12 ~ F70)

Model
Dimension(A)
of new part
Wear limit
dimension (B)
Dimension(A)
of new part
Wear limit
dimension (B)
F12 2.165 2.047 55 52
F19 2.756 2.638 70 67
F22 3.150 3.031 80 77
F27 3.346 3.228 85 82
F35 3.543 3.386 90 86
F45 3.937 3.780 100 96
F70 4.724 4.566 120 116

Revised April, 2010

Working Steel (F1 ~ F45)

Model
Effective length(A)
of new part
Wear limit effective
length (B)
Effective length(A)
of new part
Wear limit effective
length (B)
F1 10.236 7.283 260 185
F2 11.417 8.465 290 215
F3 12.795 8.865 325 225
F4 13.780 9.449 350 240
F5 14.646 9.921 372 252
F6 17.717 12.205 450 310
F9 19.685 13.780 500 350
F12 25.591 13.780 650 350
F19 27.559 14.961 700 380
F22 28.543 15.945 725 405
F27 29.528 16.929 750 430
F35 30.512 17.913 775 455
F45 31.496 18.898 800 480
F70 33.858 21.259 860 540

Section VI -- Page # 1

SECTION VI

CHARGING PROCEDURES

F SERIES HAMMER GAS CHARGE
SERVICE KIT INFORMATION


F SERIES HAMMER GAS CHARGE
SERVICE KIT INFORMATION

UNIVERSAL CHARGE KIT
PART NO. KBM21805

ITEM PART NO. QTY DESCRIPTION
1 K15587 1 CHARGE KIT ADAPTER
2 K03034 1 O-RING
3 K15588 1 CHARGE KIT ADAPTER
4 K01829 1 O-RING
5 K21806 1 HOSE ASSEMBLY
6 K08897 1 1/4" NPT FEMALE TEE
7 K08977 1 1/4" NPT PIPE NIPPLE
8 K15341 1 1/4" NPT Q.D. NIPPLE
9 K15340 2 1/4" NPT Q.D. COUPLER
10 K15350 1 200 PSI PRESSURE GAUGE
11 K15351 1 1000 PSI PRESSURE GAUGE
12 K15348 1 1/4" NPT SHUT-OFF VALVE
13 K04692 1 1/4" NPT X 4 JIC ADAPTER
14 K15339 1 4 JIC CAP
15 K21373 1 HOSE ASSEMBLY
16 K15331 * CHARGE ADAPTER
17 K15659 * 1/8" NPT X 4 JIC ADAPTER
18 K15374 1 4 JIC SWIVEL ELBOW
19 K19799 1 1/4" NPT X 1/8" NPT ADAPTER

Please note that the nitrogen gas tank and regulator/gauges set are not
included in the KBM21805 Charge Kit. The gas tank can be any convenient
size, and is readily available from most local welding gas suppliers. The
Regulator/Gauge Set should be one that is appropriate to 1000 psi
applications, similar to those referred to as "Argon" sets.

A Furukawa Rock Drill USA K15590 Regulator/Gauge Set is available for
use with the KBM21805 Charge Kit, but Furukawa Rock Drill USA does not
supply gas or gas tanks.

The K15331 Charge Adapter is no longer used, but may be ordered separately for those older
hammers that use the Schrader-type valve. The K15659 Fitting is required for use with this kit.


ACCUMULATOR CHARGING PROCEDURE

To receive the optimum performance from the hydraulic breaker, care must be taken
to maintain the proper nitrogen charge in the accumulator of the breaker. To assist with this,
Furukawa Rock Drill USA can supply a charge kit as illustrated on the opposite page.

The following is a step-by-step procedure that should be used to properly charge the
accumulator. (Note: These instructions are written for Furukawa Rock Drill USA's charge kit.
If you are not using Furukawa Rock Drill USA's charge kit, use the same procedure only
disregard the reference to item numbers.

STEP 1 The breaker should be charged at ambient temperature (not operated).
STEP 2 The customer must supply a nitrogen tank complete with a regulator.
!
USE EXTREME CAUTION WHEN HANDLING PRESSURIZED VESSELS!!

STEP 3 Connect hose assembly (15) to the regulator on your nitrogen tank.
STEP 4 Turn shut-off valve (12) clockwise until completely closed.
STEP 5 Connect the 0-1000 PSI pressure gauge (11) and Q.D. coupler (9) to the Q.D.
nipple (8).
STEP 6 Adjust your regulator to its lowest setting before opening the valve on your
nitrogen tank. Open the valve on your tank and adjust your regulator to the
appropriate accumulator charge.
(Refer to the table shown on Page 24 to select the appropriate charge.
A pressure closest to the middle of the range specified is optimum.)
STEP 7 Remove the external plug located in the accumulator charge port on top the
accumulator. Screw charge adapter (3) with O-ring (4) into the charge port.
STEP 8 Attach hose assembly (5) to charge adapter (3).
STEP 9 Remove the protective cap (19) from the accumulator, and loosen the valve (21)
approximately one turn.
STEP 10 Open shut-off valve (12) to allow the gas to enter the accumulator chamber.
STEP 11 Wait about 15 seconds. The pressure reading on gauge (11) should now be
correct. If the reading is not the proper charging pressure as shown in the table,
adjust your regulator accordingly. Once the correct pressure reading is
achieved, turn the shut-off valve (12) clockwise until it is fully closed.
STEP 12 Tighten the valve (21) completely, and replace the protective cap (19).
STEP 13 Remove charge adapter (3) from the charge port.
STEP 14 Re-install the plug into the charge port.


BACKHEAD PRESSURE TABLE

NITROGEN GAS CHARGE PRESSURE

Ambient
Temperature
KHB1G &
KHB2G
KHB3G to
KHB30G
KHB40G &
KHB50G
All F Series
Hammers

90 ~ 100 F 39 - 52 PSI 89 - 106 PSI 131 - 154 PSI 145 150 PSI
80 ~ 90 F 38 - 51 PSI 88 - 104 PSI 129 - 151 PSI 143 - 148 PSI
70 ~ 80 F 37 - 50 PSI 86 - 102 PSI 127 - 148 PSI 141 144 PSI
60 ~ 70 F 36 - 49 PSI 85 - 101 PSI 125 - 145 PSI 138 142 PSI
50 ~ 60 F 35 - 48 PSI 83 - 99 PSI 123 - 142 PSI 136 139 PSI
40 ~ 50 F 35 - 47 PSI 82 - 97 PSI 121 - 139 PSI 132 - 137 PSI
30 ~ 40 F 34 - 46 PSI 80 - 95 PSI 119 - 136 PSI 130 133 PSI
20 ~ 30 F 33 - 45 PSI 79 - 93 PSI 117 - 133 PSI 128 - 131 PSI
10 ~ 20 F 32 - 44 PSI 77 -93 PSI 115 - 130 PSI 124 128 PSI
0 ~ 10 F 31 - 43 PSI 76 - 90 PSI 113 - 127 PSI 122 - 125 PSI
-10 ~ 0 F 31 - 42 PSI 75 - 88 PSI 111 - 124 PSI 119 - 122 PSI

ACCUMULATOR PRESSURE TABLE

NITROGEN GAS CHARGE PRESSURE
Ambient
Temperature

All G Series Hammers

All F Series Hammers

90 ~ 100 F 732 - 810 PSI 908 - 956 PSI
80 ~ 90 F 719 - 796 PSI 892 924 PSI
70 ~ 80 F 706 - 781 PSI 876 - 908 PSI
60 ~ 70 F 693 - 767 PSI 860 - 892 PSI
50 ~ 60 F 680 - 753 PSI 844 876 PSI
40 ~ 50 F 666 - 739 PSI 828 860 PSI
30 ~ 40 F 653 - 725 PSI 812 844 PSI
20 ~ 30 F 640 - 710 PSI 796 828 PSI
10 ~ 20 F 626 - 696 PSI 780 812 PSI
0 ~ 10 F 613 - 682 PSI 764 796 PSI
-10 ~ 0 F 600 - 668 PSI 748 - 780 PSI

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