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Furukawa F1 Instruction Manual

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F(S)-F105E
(F1, F2, F3, F4, F5)
INSTRUCTION MANUAL

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  • Page 1 F(S)-F105E (F1, F2, F3, F4, F5) INSTRUCTION MANUAL...
  • Page 3 • • • • Keep this manual near the machine so that people who operate/control the machine can read it before operation. • • • • If this manual is lost or damaged, order a new one from Furukawa Rock Drill or its distributor.

  • Page 5: Table Of Contents

    CONTENTS Warning for prevention of danger ................0–1 Outline of machine ....................... 0–2 Location of model name and serial No................ 0–3 Location of warning label ..................... 0–4 n n n n Safety SAFETY PRECAUTIONS .................... 1–1 Safety control......................1–1 Precautions before and after starting the engine ............
  • Page 6 LONG-TERM STORAGE ....................2–20 TROUBLESHOOTING ....................2–21 HYDRAULIC OIL......................2–23 Selection of hydraulic oil ................... 2–23 Classification of hydraulic oil and grease..............2–23 Oil temperature control ..................... 2–24 Oil contamination ...................... 2–24 n n n n Inspection/Maintenance MAINTENANCE, INSPECTION AND REPAIR.............. 3–1 Periodical inspection and repair................

  • Page 7: Warning For Prevention Of Danger

    For safety, common items are described in "SAFETY PRECAUTIONS," and others are mentioned in the succeeding pages. FURUKAWA Rock Drill cannot anticipate every possible circumstances that might involve a potential hazard on operation, inspection, or repair. Therefore, the WARNINGS in this manual are not all inclusive.

  • Page 8: Outline Of Machine

    Outline of machine n n n n Specified works WARNING Do not use this breaker for any work other than the specified works. This breaker can be used for breaking, dismantling, and scaling in mines, stone-breaking, or building engineering work (railroad, dam, dismantling and construction). The applicable works are as follows: •...

  • Page 9: Location Of Model Name And Serial No

    Location of model name and serial No. • The model name and serial No. are stamped on the cylinder top of the breaker main body. Advise the distributor of the model and machine No. when placing an order for parts or asking for repair.

  • Page 10: Location Of Warning Label

    Location of warning label The warning labels show the instructions to prevent accidents caused by careless or wrong handling during inspection and repair. Follow the instructions shown by the labels as well as those shown in this manual. NOTICE If a warning label comes off or is damaged, stick it on again or replace it with a new one. 090200-04208 090200-04344 0 –...
  • Page 11 Safety WARNING Thoroughly understand the importance of "safety." Incorrect handling is very dangerous, leading to serious injury or death.

  • Page 13: Safety Precautions

    Safety precautions SAFETY PRECAUTIONS WARNING Strictly observe precautions for "safety," and take protective measures. Safety control n n n n Study instructions Severe injury or death can result from failure to follow instructions. • Study this safety manual and the instructions for both your particular hydraulic breaker and hydraulic excavator, and fully understand their controls, inspections and maintenance.
  • Page 14 Safety precautions n n n n Selecting the hydraulic excavator Install a hydraulic breaker to a proper-sized hydraulic excavator to fit with each other. If a hydraulic excavator is small for the hydraulic breaker, the excavator may lose balance and tip over. •...
  • Page 15 Safety precautions n n n n Safety clothing/Protective instruments! • Don't wear loose clothes, which can become entangled in the machinery and cause accidents. Take care of your safety clothing, especially cuffs and shoestrings. • Don't wear coveralls soaked with oil to prevent fire hazard. •...
  • Page 16 Safety precautions n n n n No fatigue or alcohol Fatigue, lack of sleep, drugs or alcohol can lead to carelessness and cause accidents. Don't operate a machine of you are in such a condition. Get a periodical medical examination to maintain a healthy life style. n n n n Safety guards When operating two or more machines at a time, arrange signs and put a safety guard in place.
  • Page 17 Safety precautions n n n n Safe work site Be sure all flammables (e.g. fuels and gas cylinder) and obstacles (e.g. tools, vehicles, wastes and other materials) are clear of work site to secure safe work site. Check and record the conditions at site, such as geographical features and soil, for potential hazards.

  • Page 18: Precautions Before And After Starting The Engine

    Safety precautions Precautions before and after starting the engine n n n n Securing firm ground! If working sites or tramming paths are rough, instability and vibration of the machine can cause accidents or property damage. • Maintain graded working sited and roadways. Operate the hydraulic excavator on even, firm ground only.
  • Page 19 Safety precautions n n n n Adjustment around the operator seat! • Set the control lever at LOCK before starting the engine so that the operating devices may not move. * For locking the machine control lever, refer to the instruction manual for the hydraulic excavator. •...

  • Page 20: Precautions For Safe Operation

    Safety precautions n n n n Don't use machine before inspecting it Machines that have not been inspected can cause unexpected accidents or machine breakdown. If any troubles arise with machine, stop operating the machine immediately and repair them. Precautions for safe operation n n n n Don't suspend any objects A load hanging from the hydraulic breaker may fall and cause serious injury, death or property damage.
  • Page 21 Safety precautions n n n n Precautions when trouble has occurred! • If trouble has occurred or if disassembly or repair is required, contact the distributor. • If trouble has occurred in the hydraulic breaker, report to the superintendent. Don't operate the hydraulic breaker before the repair is ended. n n n n Beware of electrocution •...
  • Page 22 Safety precautions n n n n Beware of underground utilities • Before operating, verify location with control offices of underground cables, gas pipes, water pipes and drain pipes and other underground utilities. • If a gas pipe get damaged during operating, keep flammable materials away from the damaged gas pipe and report the damage to a fire station and neighbors immediately.
  • Page 23 Safety precautions n n n n Beware of the hydraulic breaker operation If the hydraulic breaker or the rod runs into the cab, serious injury or death can result from it. Always be careful of the hydraulic breaker operation to prevent accidents. n n n n Beware of the rod end The rod end is sharp and dangerous.
  • Page 24 Safety precautions n n n n Operate the hydraulic excavator carefully on inclines Operating the hydraulic excavator on inclines can cause tipping over because of the instability. Maintain the supporting surface level for operation. Operating or stopping the hydraulic breaker abruptly can cause tipping over because on the inertia. Always operate the breaker slowly on inclines.
  • Page 25 Safety precautions n n n n Don't operate the hydraulic breaker on unstable ground If operating the hydraulic breaker on potentially unstable ground, vibrations and their impacts from the operation can cause to tip over unexpectedly. Maintain graded working site before you start breaking. n n n n Keep away from cliffs and embankments Keep as far away from cliffs and embankments as possible because ground may be soft.
  • Page 26 Safety precautions n n n n Stop operating when something is wrong with the machine If a part breakage, strange noise or other trouble happens during operation, stop operating the machine immediately. Operating the machine without repairing it can cause serious machine breakdown and accidents. If something is wrong with the machine, check the cause of the trouble immediately and perform maintenance to prevent breakdown.
  • Page 27 Safety precautions n n n n Postpone operation if visibility is poor If visibility is not good enough to work, postpone the operation until visibility become better. When expecting a strong wind, heavy rain or snow, and other rough weather which may prevent safe operation, contact your supervisor to ask for suspending the operation.
  • Page 28 Safety precautions n n n n Tram carefully on slopes • The machine might tip over when tramming on slopes. • Make sure that the machine has the manufacturer's recommended gradeablity against the angle of a slope to tram. • Always use caution and tram slowly when on a slope.

  • Page 29: Precautions For Parking And Stopping The Machine

    Safety precautions Precautions for parking and stopping the machine n n n n Precautions for parking and stopping the machine • Stop the hydraulic excavator on flat and firm ground. • When leaving the machine, set the hydraulic breaker on the ground, and take the key with you to prevent unauthorized people from operating the machine.

  • Page 30: Precautions For Maintenance

    Safety precautions Precautions for maintenance n n n n Inspect the machine after operation • Perform inspections of bolts, oil leakage, cracks, damage, wear and hoses after operation every day. • If something is wrong with the machine, perform maintenance and contact your work shop or manufacture to repair or replace the machine, if necessary.
  • Page 31 Safety precautions n n n n Beware of flying bits of steel • When hammering pins, bushings, rods or other hard steel parts, flying pieces can cause eye damage. • Always wear safety glasses and helmet when performing maintenance and use a brass punch between a part and hammer.
  • Page 32 Safety precautions n n n n Beware of hydraulic oil • High pressure diesel oils and hydraulic oils can cause serious injury or death if they get the skin or eyes. Use pasteboard or woodenboard to check oil leakage, not your bare hands. Hydraulic oil leakage from a pin hole is sometimes invisible.
  • Page 33 Safety precautions n n n n Handle nitrogen gas carefully. • Relieve gas from the accumulator before removing The accumulator has been enclosed with high pressure gas, if removing the accumulator without relieving gas from it, the accumulator cover and other parts can blow up and cause serious injuries.
  • Page 34 Safety precautions n n n n Weld safely Serious accidents can result from unsafe welding practices. Weld only in the secure work area for maintenance. Before welding: • Remove battery terminals to prevent breakage of electric devices. • When welding near batteries, remove batteries form the machine to prevent from explosions. •...
  • Page 35 Safety precautions n n n n Check the machine after the maintenance • After maintenance, run the engine at low idle and check for oil and water leakage areas where the maintenance was performed. • Move the operating levers slowly to check their functions. •...

  • Page 37: Operation

    Operation...

  • Page 39: Name Of Components And Specifications

    Name of components and specifications NAME OF COMPONENTS AND SPECIFICATIONS Name of components and specifications n n n n F1~F5 Charging valve Accumulator Back head P-port T-port Valve Adjuster Through bolt Cylinder Front head Rod pin Grease nipple n n n n Standard specifications Model Item Mass of body (incl.

  • Page 40: Function Of Each Part

    Outside dimensions FUNCTION OF EACH PART n n n n Through bolt Front head, cylinder and back head of breaker body N2 gas are secured with four through bolts. Cylinder Accumulator Hydraulic circuit for reciprocating the piston and valve are built in. The cylinder is the heart of the Back head breaker body .

  • Page 41: Outside Dimensions

    Outside dimensions OUTSIDE DIMENSIONS Outside dimensions of hydraulic breaker n n n n F1~F5 1314 1208 1119 1014 ∅36 ∅45 ∅52 ∅60 ∅68 Outside dimensions of bracket n n n n Side Bracket n n n n Bracket 2 – 3...
  • Page 42 Outside dimensions n n n n B-box n n n n T-box Model Item Side bracket 1015 1115 1230 1352 Total Bracket 1009 1095 1255 1335 1458 length B-BOX 1241 1395 1507 1689 Dimen- T-BOX 1050 1159 1255 1369 sion Outside of bracket Inside of bracket ∅45...
  • Page 43 Outside dimensions n n n n Top bracket (T-box) Model Item Dimension (mm) 2 – 5...

  • Page 44: Types Of Rod And Major Applications

    • Furukawa rods come in a moil point, wedge point, flat rod, and rod with cemented carbide core. In general, the moil point is used frequently, but select an appropriate rod according to the nature of work and the characteristics of the object to break.

  • Page 45: Oil Hose Plug And Cap

    Outside dimensions Oil hose plug and cap NOTICE When attaching/detaching the oil hose plug and union cap, clean them well to prevent entry of dust. Oil hose plug The oil hose plug is used to plug the hose attached to the hydraulic breaker.

  • Page 46: Mounting On Base Machine

    Mounting on base machine MOUNTING ON BASE MACHINE WARNING Two persons are necessary for mounting/dismounting the hydraulic breaker, so determine signals for operation in advance. Be sure to use a crane to handle brackets, pins, and other heavy objects. When the pin retaining bolt is removed during operation, the mounting pin will come off, and the hydraulic breaker will come off the hydraulic excavator, leading to injury or death.
  • Page 47 Mounting on base machine 4. When the arm pin is inserted, raise the boom, and place the breaker on the timber. Extend the bucket cylinder, and insert the pin into the hole in the bucket link. 5. Install the stop ring, and install the retaining bolt. Bolt locking is of a double-nut type. Tighten the nuts firmly.
  • Page 48 Mounting on base machine 9. Start the engine of the base machine, and raise the boom. Then operate the bucket cylinder to straighten the twisted connection hose of the hydraulic breaker. 10. Turn the high-/low-pressure stop valve on the hydraulic breaker pipe at the end of the arm by 90 degrees (the line on the head shows the direction of flow), and connect the hydraulic circuit.

  • Page 49: Operation Procedures (Breaking)

    Operation procedures (Breaking) OPERATION PROCEDURES (BREAKING) CAUTION Only those who have completed the technical course for operation of vehicle type construction machines (for dismantleing) and mastered the method of operation can operate the hydraulic breaker. Operate the base machine in accordance with the operation textbook used during the training course and the operation manual for the base machine.

  • Page 50: Breaking Operation

    Operation procedures (Breaking) n n n n Security • Before starting operation, check the topographical and geological conditions of the work site, and pay sufficient attention to cracks in the ground and collapse of buildings. • Station guards, arrange fences, and take other safety measures to protect pedestrians and general vehicles.

  • Page 51: Optimal Thrust

    Operation procedures (Breaking) 3. Step on the breaker pedal to operate the breaker. NOTICE When the thrust drops during hammering, operate the boom to increase the thrust. 4. After braking concrete, return the pedal to the original position immediately. Repeat the above operation for breaking. Optimal thrust In order to effectively use the breaking force, appropriate thrust must be given to the breaker.

  • Page 52: Direction Of Thrust

    Operation procedures (Breaking) When the machine hammers a rock while the front of the base machine is lifted, the vibration during hammering will be transmitted also to the crawler, so avoid such operation for protection of the crawler. Exercise care so that thrust will be applied at all times during hammering operation.

  • Page 53: Precautions For Operation

    1. Stop operation when hoses are vibrating abnormally. Check the hoses on the high-pressure and low-pressure sides of the breaker for abnormal vibration. If they are vibrating abnormally, ask your Furukawa dealer for inspection. 2. Stop operation right after breaking. (Avoid idle blows as much as possible.) After breaking rock, stop striking immediately.
  • Page 54 Operation procedures (Breaking) 3. Do not move rock. Rolling or falling a rock with the rod end or bracket side by using the boom or arm of the base machine as shown in the figure will result in breakage of the breaker mounting bolt or bracket, breakage and galling of the rod, and damage to the arm and boom.
  • Page 55 Operation procedures (Breaking) 5. Do not hammer continuously for more than one minute. If a rock cannot broken after hammering the same position for one minute, change the hammering position. Continued hammering of the same place for a long time will cause abnormal wear of the rod. 6.
  • Page 56 Operation procedures (Breaking) 8. Do not break rock in water or mud. Do not put any portion other than the rod in water or mud, Otherwise, water or mud will enter the hydraulic oil, leading to early failure of the breaker or base machine. 9.

  • Page 57: Storage After Operation

    Operation procedures (Breaking) Storage after operation CAUTION The rod is hot right after hammering, so do not touch it. When operation is suspended or completed When operation is suspended or completed, move the base machine to a flat ground, remove mud from the breaker body, and vertically lower the hydraulic breaker.

  • Page 58: Long-Term Storage

    When using the machine after long-term storage When using the hydraulic breaker after long-term storage, ask your Furukawa dealer for inspection. NOTICE Sudden operation of the hydraulic breaker under high pressure will cause seizure of the piston and cylinder.

  • Page 59: Troubleshooting

    Troubleshooting TROUBLESHOOTING The table below is prepared for the person in charge of maintenance to be able to take corrective measures immediately when hydraulic breaker trouble occurs. Understand the details of the situation shown below when trouble occurs, and then contact the distributor. Situation Cause Correction...
  • Page 60 Troubleshooting Situation Cause Correction (II)High-pressure oil is supplied sufficiently to the oil inlet of the breaker (f) Failure of the inside of (f) Ask the distributor for an cylinder overhaul • Entry of foreign substances (III) The number of blows increased 3.

  • Page 61: Hydraulic Oil

    In general, hydraulic oil specified by the base machine maker is recommended. Our company recommends the following hydraulic oil. Contact your Furukawa Rock Drill dealer in the following cases: a. When the machine is operated in a place where our recommended hydraulic oil is unavailable.

  • Page 62: Oil Temperature Control

    Hydraulic oil Oil temperature control • The hydraulic breaker is operated by the hydraulic power source of construction machinery (hydraulic excavator, etc.). After warming up the base machine, start the operation when the temperature is approx. 40°C. Usually, the hydraulic oil temperature of the hydraulic breaker and base machine circuit must be controlled between 40 and 60°C.

  • Page 63: Inspection/Maintenance

    Inspection/Maintenance...

  • Page 65: Maintenance, Inspection And Repair

    Maintenance, inspection and repair MAINTENANCE, INSPECTION AND REPAIR A hydraulic breaker is an attachment of a hydraulic excavator or the like. Therefore not only the inspection and repair mentioned in this manual but also those for the base machine (hydraulic excavator, etc.) are very important.
  • Page 66 Maintenance, inspection and repair Standard of judgment Parts Check points Description Method Pin and bush Visual (1) No pin and bush must be worn. (2) All pins and bushes must be greased fully. Oil hose Visual (1) No oil leakage. Check the oil hoses.

  • Page 67: Daily Inspection / Inspection And Maintenance Before Operation

    Maintenance, inspection and repair Daily inspection / inspection and maintenance before operation NOTICE Before operation, be sure to check the following items and lubricate respective parts. Inspection item Location Correction • Accumulator mounting bolt • Check missing bolts • Looseness, falling-off, or •...
  • Page 68 Maintenance, inspection and repair Inspection item Location Correction • Abnormal • Rod • If the rod is burred, abrasion cracks in rod deformed, or its end is broken, correct with a grinder • If the rod is extremely worn, replace it •...

  • Page 69: Tightening Torque

    Maintenance, inspection and repair Tightening torque Breaker main body n n n n F1-F5 1: Accumulator/Bolt 2: Through bolt Nut 3: Accumulator/plug 4: Accumulator/cap 5: Connector 6: Screw plug Unit: Nžm Model Location Bolt size M16×2.0 M16×2.0 M16×2.0 M16×2.0 M20×2.5 Accumulator/Bolt HEX socket size Tightening torque...
  • Page 70 Maintenance, inspection and repair Side Bracket / bracket n n n n F1-F5 Unit: Nžm Model Location Bolt size M16×2.0 M18×2.5 M20×2.5 M22×2.5 M24×3.0 HEX head size Bracket Nut HEX size Tightening torque B-box n n n n F2-F5 Unit: Nžm Model Location Bolt size...
  • Page 71 Maintenance, inspection and repair T-box n n n n F2-F5 Unit: Nžm Model Location Bolt size M12×1.75 M16×2.0 M20×2.5 M20×2.5 HEX head size Top cover Nut HEX size Tightening torque 3 – 7...

  • Page 72: Wear Limit Dimensions For Consumable Parts

    Wear limit dimensions for consumable parts WEAR LIMIT DIMENSIONS FOR CONSUMABLE PARTS F1-F5 Unit (mm) n n n n Rod pin Dimension (A) of Wear limit Model new part dimension(B) Unit (mm) n n n n Front bush Bore (A) of new Model Wear limit of bore part...
  • Page 73 Inner length (A) of Wear limit inner Model new rod length(B) of rod Measurement n n n n Piston Unit (mm) Dimension (A) of Wear limit Model new part dimension(B) NOTICE Be sure to use "genuine Furukawa parts" for replacement. 3 – 9...

  • Page 74: Replacement Of Rod & Front Bush

    Replacement of rod REPLACEMENT OF ROD & FRONT BUSH • When a rod is used for many hours, it is deformed or burrs are produced. In such a case, deburr with a grinder. • If the rod end is worn, the rod is liable to slip. Regrind the rod end to make it smooth. •...

  • Page 75: Removing From T-Box And Side Bracket

    Replacement of rod Removing from T-box and side bracket 1. Remove the screw plug on the side of the front head with an Allen wrench. Screw plug Screw plug 2. After removing the screw plug, apply an Allen wrench or a screwdriver to the smaller pin to remove the stop pin.
  • Page 76 Replacement of rod 4. Pull out the rod. Check the removed parts for abrasion, damage, and scratches. Remove burrs and swelling especially from the rod pin. Stop pin Screw plug Rod pin 5. When assembling the rod pin, align the rod pin hole in the front head with the groove in the rod, and insert the rod pin.

  • Page 77: Adjustment Of Adjuster

    ADJUSTMENT OF ADJUSTER NOTICE In fact, adjustment is necessary only when the breaker is mounted on a base machine which is out of the applicable base machine range. Avoid unnecessary adjustment. Adjust the adjuster while the breaker is in the stop condition. When exceeding the adjustment range of the adjuster, the hydraulic oil may leak.

  • Page 78: Charging The Accumulator With N2 Gas And Inspection Of Charge Pressure

    CHARGING THE ACCUMULATOR WITH N2 GAS AND INSPECTION OF CHARGE PRESSURE WARNING Never use any gas other than nitrogen gas. CAUTION When charging only the accumulator with N2 gas, make sure that the body and cover of the accumulator are tightened securely. NOTICE Be sure to use a three-way valve for charging gas.

  • Page 79: Inspection Of Charge Pressure

    Inspection of charge pressure 1. Install the adapter (2) and pressure gauge (5) to the three-way valve (4). (Make sure that the O-rings (6) and (7) are installed in the adapter (2).) 2. Tighten the cap and relief valve installed in the three-way valve (4). 3.

  • Page 80: Charging Accumulator With N2 Gas

    Charging accumulator with N2 gas 1. After performing the inspection steps 1 to 4 of charge pressure, remove the cap from the three-way valve (4). 2. Connect the charging hose (3) to the three-way valve (4) and N2 gas cylinder (1). 3.
  • Page 81 Overseas Trading Division 15-9, Uchikanda 2-chome, Chiyoda-ku, Tokyo, Japan. Book No. : F(S) - F105E Tel : 03-3252-8151 Fax : 03-5297-3944 Date of Issue : Sep.2001...

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