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Table of Contents
Summary of Contents for Maruzen KH193
- Page 1 HYDRAULIC PILE DRIVER MODEL KH193 SERVICE MANUAL MARUZEN KOGYO CO., LTD.
- Page 2 FOREWORD The purpose of this Maruzen Hydraulic Pile Driver Model KH193 service manual is for supporting and instructing all personnel involved in repair and maintenance for KH193 Hydraulic Pile Driver. This service Manuals provides detailed information including safety alert, operating instruction and step by step repair and maintenance procedures.
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Page 3: Table Of Contents
CONTENT 1. SPECIFICATIONS ........................4 2. OUTSIDE VIEW..........................4 3. STRUCTUAL DRAWING ......................5 4. OPERATING PRINCIPLE ......................6 5. SPECIAL JIG LIST ........................9 6. DISASSEMBLY ........................... 10 6-1 PREPARATION BEFORE DISASSEMBLING ..............10 6-2 DISASSEMBLING OF HANDLE..................10 6-3 TO REMOVE ACCUMULATOR. -
Page 4: Specifications
１ SPECIFICATIONS Dimensions L486 X W273 X T146 Weight 20 kg Hydraulic Pressure 8 -11 MPa Max Allowable Pressure 20.6 MPa Operating Flow 20 L/min Impact Numbers 1920 b.p.m Connection 3/8 ” Coupler Allowable Back Pressure 2.5 MPa Recommended Hydraulic Oil ISO VG32/46 or Equivalent Max Driving Diameter Φ50mm... -
Page 5: Structual Drawing
Gas chamber ３ STRUCTUAL DRAWING Diaphragm Operation grip Upper chamber 1st valve chamber 2st valve chamber 3rd valve chamber Valve rod Control valve Valve center chamber Upper piston chamber Inner tube Piston Intermediate chamber Lower piston chamber Anvil... -
Page 6: Operating Principle
４ OPERATING PRINCIPLE Fig.1 The hydraulic oil that has flowed in from the inlet flows out from the 3rd valve chamber to the outlet, so the pile driver does not operate. Fig.2 When the operating grip is pushed down, the cam pushes the valve rod and the circuit to the outlet is closed. - Page 7 Fig.3 While the piston pushed up, some of the hydraulic oil that flows from the inlet into the upper chamber flows into the accumulator chamber. And the pressure pushes up the diaphragm and compresses the gas in the gas chamber. When the end of the piston reaches the intermediate chamber,...
- Page 8 Fig.5 While the piston is being pushed down, hydraulic oil in the gas chamber is released and supplied from the 1st valve center chamber thorough passage to the upper piston chamber to increase the pressure in the circuit. The tip of the piston hits the head of the anvil, which transfers this striking energy and hits the stake or pipe.
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Page 9: Special Jig List
５ SPECIAL JIG LIST Wrench M68 M71053 Handle T-726 Nut M71054 Bolt T-727 Gas charging valve T-2411... -
Page 10: Disassembly
６ DISASSEMBLY 6-1 Preparation before disassembling ① Carry out disassembling in clean place. ② To Prevent mis-assembling, all the disassembled main parts should be marked with white pen. ③ To attach the tag which is written the remarkable notices to the main parts to prevent mis-assembling. -
Page 11: Disassembling Main Body
6-4 Disassembling main body ① Heat the M14 nut with a gas torch burn anaerobic adhesive. (2 parts) *Be careful: When heating the implant part of the draw bolt, wait until the nitrogen gas is completely released before starting work. ②... -
Page 12: Taking Off The Oil Seal
OG-60 6-5 Taking off the oil seal. ① Taking off O-ring (OG-60) ② Taking off dust seal with flat blade screw driver. ③ Pierce u cup packing by awl and remove it. *DO NOT RE-USE U CUP PACKIN AND DUST SEAL. U CUP PACKING DUST SEAL 6-6 Disassembling the valve body... - Page 13 Plug ⑤ Heat 1/8 taper plug with a gas torch and burn the anaerobic adhesive. ⑥ Remove 1/8 taper plug by hex wrench 5mm. ⑦ Loosen orifice assembled as figure by hex wrench 3mm and remove it Orifice with pressing carefully for not to fall it.
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Page 14: Disassembling Inner Tube
6-7 Disassembling inner tube Plug ① Fix the A part of the inner tube by vise. Spring * When fixing each part with a vise, use a Steel ball copper plate or the like to fix it so that it will not be scratched. -
Page 15: Disassembling The Post Cover
6-9 Disassembling the post cover. ① Fix the post cover part by vise. ② Take off the M8x30 cap bolt (8pcs) and NL8DP Nord lock washer (8pcs) by hex wrench 6mm. ③ Remove the front cap. ④ Remove the flange. ⑤... -
Page 16: Inspection After Disassembly
７．Inspection after disassembly Replace the U-cup packing and Dust seal. ① Replace O-ring which is deformed, wear, scratch or harden. Replace the diaphragm which is cracked or wear. ② Make sure if there is any deformation, wear and scratch on the surface of each part. ③... - Page 17 Sliding part Control valve Inner tube Piston Cylinder Valve body...
- Page 18 Marginal wear Standard Limited Description dimension dimension Piston（Hitting surface） 150ｍｍ 149ｍｍ 1ｍｍ Bush, Anvil（Hitting point） 73mm 73ｍｍ 71ｍｍ Cum part（Gap） 1.2ｍｍ 5.1ｍｍ...
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Page 19: Assembling
８．Assembling 8-1 Assembling accumulator ① Clean the inner diameter of the shell and then fix by vise. ② Clean the lid and fit the diaphragm into the groove. ③ in the groove of the lid. ④ Apply the hydraulic oil to inner diameter of the shell and perimeter of the diaphragm. -
Page 20: Attaching The Draw Bolt
8-2 Attaching the draw bolt. ① Fix the shell part by vise. ② Degrease the M14 female threaded part of the valve body and the threaded part of the draw bolt. ③ Apply anaerobic adhesive high-strength screw lock (1305N) to the shorter thread part of the draw bolt. -
Page 21: Assembling Valve Body
8-4 Assembling valve body ① Apply the hydraulic oil to the O-ring OP-12.5-1B (OP-5) and back up ring (OBP-5), OP-5 OBP-5 and then attach them to the valve rod. OP-14 ② Apply the hydraulic oil to the O-ring (OP-14, OP-12.5-1B) and back up ring (PBP14), and then attach them OBP-14 to the valve guide. -
Page 22: Attaching Oil Seal
⑪ Wrap the sealing tape around taper screw of the hydraulic hose. ⑫ Attach the coupler by spanner 19mm and 24mm. Tightening torque: 56N・m ⑬ Attach the connector and seal washer (W18S1) by spanner 22mm. Seal washer Tightening torque: 56N・m ⑭... -
Page 23: Assembling The Operation Grip
8-6 Assembling the operation grip. ① Clean the inner diameter part of the operation grip. ② Apply the hydraulic oil to the DU bush. ③ Set the special jig tools, and press it by hand press machine. 8-7 Assembling the post cover. ①... -
Page 24: Assembling The Main Body
8-8 Assembling the main body. ① Fix the part A of post cover by vise. ② Insert the cylinder Assy’ into the inner diameter of front cap. ③ Apply the hydraulic oil to the control valve and inner tube. ④ Insert the inner tube into the inner diameter of the piston. -
Page 25: Assembling Main Body
8-9 Assembling main body (Accumulator part.). ① Degrease the cap bolt M12x35 (2pcs), M8x15 (4pcs), screw part where attaching. ② Set the accumulator on the valve . M12×25 ③ Apply anaerobic adhesive low-strength Cap bolt screw lock (1342J). ④ Tighten the M8x15 cap bolt by hex wrench 6mm. -
Page 26: About Hydraulic Oil
Completed 9. About Hydraulic Oil 9-1 Characteristics and species Hydraulic oil is the liquid to be used in hydraulic systems as a transmitting agent of power. It effects lubricating, anti-rust and cooling etc. To fulfill the functions of hydraulic tools, always use the suitable hydraulic oil. Industrial Hydraulic Oil・・・ISO Viscosity Grade VG32、46 Species・・・・・Wear Resistant Hydraulic Oil Recommended Oil・・・・・・Shell Talus 32... -
Page 27: Trouble Shooting
10 Trouble Shooting Symptom of Trouble Cause Countermeasure Impact power is weak Replace diaphragm Hoses shaking Less nitrogen gas pressure Re-charge nitrogen gas abnormally Impact power is weak Looseness of through bolt nut Re-tighten Disassemble and clean the Impact power is weak Mud infiltrates the anvil anvil. -
Page 28: Notice On Long Storage
11 Notice on Long Storage Connect the pile driver to the extension hose of the hydraulic unit, push the anvil from the bottom of the post cover of the pile driver, and push the piston to the upper limit. Replace the 1/8 taper plug on the front cap with a grease nipple and grease it with a grease gun.
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