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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

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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

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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

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1. ABOUT THE Hammer

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

Page 41


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

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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

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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

Page 59


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.

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

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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.

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 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.

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 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.

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

Page 77


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

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

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.

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

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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.

Maverick Equipment Manufacturing, Inc. U.S.A. - Product Technical Manual

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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.

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Page 89


9.TOOL

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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

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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

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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

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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

Page 101


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

Page 103


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

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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

Page 111


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

Page 113


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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Maverick Technical Manual