MARUZEN KOGYO BH221 User manual

FOR THE SAFETY PURPOSE, PLEASE READ THIS MANUAL THROUGHLY
BEFORE ATTEMPTING TO USE THIS BREAKER. ANY FALES
OPERATING PROCEDURES WILL CAUSE DAMAGES OF THE MACHINE.
ALWAYS KEEP THIS MANUAL TO AN EASILY ACCESSABLE PLACE.
HYDRAULIC HANDHELD BREAKER
MODEL BH221（230）
OPERATING MANUAL
MARUZEN KOGYO CO., LTD.
CAUTION
(Revised Mar.14, 2013

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FOREWORD
This manual is an important part of your equipment. It provides
rules and guidelines which will help you use this machine safely and
effectively. You MUST familiarize yourself with the functions and
operations by reading the manual thoroughly before you begin using
this machine. For your safety, it is especially important that you
read and observe all precautions in this manual and labels on the
machine. The precautions MUST be followed strictly at all times
when performing operation and maintenance. * Fail to follow the
guidelines and safety alerts in the manuals and on the machine, or
use this machine in alternative ways from the manuals may result in
system failure or serious personal injury.
Keep this manual with the equipment or in an easily accessible place
in all times for future reference. Make sure all personnel involved in
working on this machine can consult it periodically. In case this
manual should be lost or damaged, immediately contact us or your
dealer to purchase a new copy.
We recommend you always use Maruzen genuine components and
parts. Replacing components and parts from other sources may cause
damages to this machine and endanger operators.
MARUZEN KOGYO CO., LTD.
155-8 NAGABUSE, MISHIMA-SHI,
SHIZUOKA-KEN, 411-0824, JAPAN

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CONTENTS
Safety Information .............................................................. 4 ～ 7
Safety Alert Classifications ........................................... 4
Safety Alerts .................................................................. 5 ～ 7
Introductions ....................................................................... 8
Specifications & Descriptions ............................................. 9
Precaution Labels and Positions ........................................ 10
Inspection before Each Operation ...................................... 11
Guidelines ........................................................................... 12 ～ 13
Operation............................................................................. 13 ～ 14
Suitability of Power Source ................................................ 15
Periodically Inspection ....................................................... 16
Installation of Side Handle................................................. 16
Tools & Applications ........................................................... 16
Troubleshooting ................................................................... 17 ～ 18
Exploded View I .................................................................. 19
Parts List ............................................................................. 20 ～ 21

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SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels
are given in this manual and affixed to the machine to give
explanations of situations involving potential hazards and of the
methods of avoiding such situations.
SAFETY ALERT CLASSIFICATIONS
The following safety alert symbols are used to inform you that there is
a potential hazardous situation that may lead to personal injury or
damage.
In this manual and on machines labels, the following safety alert
symbol are used to express the potential level of hazard.
** Safety alert symbols are to emphasize all operation which, if not
strictly followed, could result in a life-threatening situation, bodily
injury or damage to equipment.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, could result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate
injury.

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DO NOT OPERATE THE MACHINE UNLESS THE FOLLOWING SAFETY
INSTRUCTIONS HAVE BEEN THOROUGHLY READ AND UNDERSTOOD!
Do not operate the equipment if you are
or if your
1. taking medication, feeling drowsy, feeling unwell or feeling
tired.
2. under the influence of drugs or alcohol.
3. hands, feet, lower back or other parts of your body hurt or
being injured.
* Failure to observe this precaution can result serious injury or
even death.
WARNING
WARNING Before operating the equipment, be
sure to ware personal protective
equipments such as follows:
1. Helmet
2. Protective goggles
3. Protective boots
4. Safety gloves
5. Hearing Protection
SAFETY ALERTS

6
CAUTION Do not touch the machine with your bare
hands
1. The oil tank may become hot under continuous running
.
Do not touch the equipment with your bare hands.
2. Tools may become hot under continuous use, make sure
to ware gloves before any contact with the tools.
* Failure to observe this precaution can result getting
burned
CAUTION When lending someone the equipment
Make sure the safety instructions have been thoroughly
read and fully understood by the person who is going to use
the equipment.
WARNING Avoid Blank Hammering
Operating the equipment horizontally may cause the
chisel’s sudden flying out.
Excessive blank hammering may be considered equipment
abuse and may cause equipment damage.
Failure to observe this precaution can result damage to the
breaker.

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WARNING Never operate the breaker when
bystanders are in the work area
1. Do not operate the breaker if any people are within
the area where flying debris or movement of the
breaker may injure them.
2. For preventing flying debris, make sure protection
fences are being set up.
Failure to observe this precaution can result personal
injury.
WARNING Be special cautions to high pressure
gas
1. High pressure gas was held inside the accumulator of
the breaker.
2. Do not loosen the nut unless it is necessary for
maintenance.
Failure to observe this precaution can result serious injury

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INTRODUCTION
1. This hydraulic breaker is designed to be used for the following
purposes.
(1) Breaking concrete and asphalt
(2) Anchoring and pile driving
(3) Digging or breaking hard soil
(4) Compacting soil
(5) Cutting asphalt
2. DO NOT operate this breaker on the following situations:
(1) drench part of the breaker or whole breaker into water or
seawater.
(2) connect with power source which its oil flow and pressure exceeds
prescribed.
(3) operating with oil temperature below 10℃ or over 100℃.
(4) use shank which its size is different from prescribed
(5) attach to other construction machinery.
(6) use the equipment for purposes other than stated in this manual.

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SPECIFICATIONS & DESCRIPTIONS
Overall Weight 22kg (Without tool)
Overall Dimensions 703mm X 421mm
Working Pressure 80～120kgf/㎠
(7.8～11.8Mpa)
Max. Pressure 210kgf/㎠
(20.6MPa)
Oil Flow 15～30L/min
Blow Per Minute 1100～1800bpm
Shank Size Hex. 1” X 4 1/4”
Coupling 3/8” Couplers
Max. Hose Length 1/2” X 20m
Accumulator
Handle
Control Lever
High Pressure Hose
Side Handle
Coupler (Male)
Coupler (Female)
Tool
Latch

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PRECAUTION LABELS AND POSITIONS
* Make sure labels are legible. Replace new
one when they are illegible.

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INSPECTIONS BEFORE EACH OPERATION
For the purpose of keeping the breaker in good
condition, make sure the following inspection items
are done each time before using. (Refer the drawing
on the right)
Inspection Items Countermeasures
1. Loose nut
Tighten the loosen nut
2. Loose handle attachment Tighten handle attachment
3. Loose hose attachment Tighten hose attachment
4. Cracks on handle grips
Replace new one
5. Wears found on Latch Replace new one
6. Damage, cracks on tool Replace new one
7. Loose bolts on side handle*
Tighten the loosen bolts
8. Oil leakage
Ask your dealer for repair and
service
9. Cracks on control lever Replace new one
* Optional
1. Loose nut
2. Loose
handle attachment
3
.
Loose
hose attachment
4. Cracks on handle grips
5. Wear Latch
Wears in Latch
6. Damages, cracks on tools
Bolts inside
8. Oil leakage
8. Oil leakage

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GUIDELINES
Following these guidelines while using this breaker:
1. When intend to use other power source (other than Maruzen
hydraulic power units), make sure the pressure of the power
source is in the range of 140 ～ 210kgf/㎠ and oil flow is in the
range prescribed
2. When connecting and disconnecting couplers, make sure dirt, dust
and other foreign substance does not enter or attach to couplers
and hoses.
3. Make sure the power source is OFF when connecting the breaker
to the power source.
4. Maruzen original tools are highly recommended. Consult your
dealer for more specifics of tools.
5. If the oil temperature is below 10℃, warm up the breaker before
start operating.
6. Pay attention to the followings while operating the breaker.
(1) Be cautious for not being injured by the front of the tool.
(2) Be cautious for not being tripped by the extension hoses.
(3) Make sure there are no obstacles at jobsite. (Be cautious not
being tripped by obstacles while operating)
(4) While pulling out the breaker from the broken objects, be
cautions for not being fall over.
(5) Make sure the breaker was placed in horizontally. Fail to
place the breaker horizontally after operating can cause
injury by sudden falling of the breaker.
(6) Be cautious not to injure your back while lifting the breaker.
7. In case of sudden hydraulic hose breakage and hydraulic oil belch
out. STOP the power source IMMEDIATELY.
8. Replace new hoses when they are worn or when oil exudes from
them.
9. When detach couplers, a small amount of oil may slip out. Make
sure that surrounding area does not get dirty by oil.
10. When detach from power source, attach two hoses to each other.
CAUTION

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11. When frequently attach and detach to the power source, hydraulic
oil will decrease accordingly. Always make sure the hydraulic oil
level before operating and refill if necessary.
12. After the operation, use tool to push up the piston.
Immediately STOP the power source if the breaker does not stop after
releasing the control lever. Ask Maruzen dealer for repair and
service before the next operation.
OPERATIONS
CAUTION
2.
Con
nect the other side of extension
hose ② to the power source ③
1. Con
nect hydraulic breaker
’
s standard
hose ① and extension hose ②

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4. Start engine in power source and let engine run for a while to
warm up the machines.
3. Unlock the latch ④on breaker, load
the tool⑤ and lock the latch again.
5. Clasp the handle grip⑥, bear down
the breaker, clasp the control lever
gently and let the breaker start
running.

15
SUITABILITY OF HYDRAULIC POWER SOURCE AND BH163 BREAKER
Refer to the following charts while using with power source other than Maruzen power units.
(1) Suitability of oil flow (Pressure is in the range of 120 ～ 210kgf/㎠)
BH163
Activation
Performance
Effect on BH201 breaker
Recommendation
Counter
measure
Over 28L/min △ × ×Damage of accumulator,
valves and etc × Use of flow control
valve
22～28L/min ○ △Strong recoil △valves wear out easily ○
Reduce the
number of
rotation of the engine
18～22L/min ○ ○ ○ ◎ ―
14～18L/min △ △ ○ ○ N/A
Under 14L/min × × ― × N/A
 Use of orifice is an alternative to adjust oil flow of the power source.
(2) Suitability of pressure (Oil flow is in the range of 20 ～ 25L/min)
Power Source
Activation
Performance
Effect on BH201 breaker
Recommendation
Countermeasure
Over 210kgf/㎠ ○ ○ ×Damage of accumulator,
valves, hoses and etc × Pressure relief valve
140～210kgf/㎠ ○ ○ ○ ◎ ―
100～140kgf/㎠ ○ △ ○ ○ ―
80～100kgf/㎠ △ △ ○ △ ―
Under 80kgf/㎠ × × ― × N/A
＊ Oil flow has greater effects on breakers then pressure.

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PERIODICAL INSPECTION
Ask your dealer for the periodical inspections.
Inspection Items
Operating Hours
Nitrogen gas charge in accumulator
300 hours or 1 Year
Replacement of accumulator diaphragm
500 hours or 2 years
Replacement of Valve Rod O ring
500 hours or 2 years
Replacement of U
-
cup packing
500 hours or 2 years
Replacement of each O ring
M
ore than 3 years
INSTALLATION OF SIDE HANDEL
(1) Place side handle on the flat part of front end of the breaker.
(2) Set washers with bolts. Screw the bolts with torque 3.5kgf・m
(34.3N・m)
(3) Make sure if side handle has been installed firmly.
TOOLS AND APPLICATIONS
Tools Dimensions Applications
Moil Point Breaking
Concrete Chisel Breaking
Asphalt Chisel Cutting and Breaking
Shovel
Cutting and digging
out asphalt
Tamping Rammer
Compacting soil or
sand
L = 400mm
L = 400mm
L = 400mm
W = 76mm
L = 400mm
W = 140mm
L = 285mm
W= 180mm

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Symptoms Causes Countermeasures
Grip the control lever but does not start
1.
Power source is off (Switch lever is
not in ON position)
2. Hoses are not connected
3. Couplers are not connected properly
4. Relief valve pressure is set too low
5. Damage of control lever
6. Control lever is not functioning
7. High pressure side and oil return
side was connected inversely
1.
Start the power source (Turn the
switch lever to On position)
2. Connect hoses
3. Check out if all the couplers have
been connected properly
4. Adjust pressure to 140～210kgf/㎠
(13.7～20.6MPa) *
5. Replace a new control lever *
6. Disassemble breaker, clean and
remove dirt and dust between
control lever and valve body *
7. High pressure hoses is connected to
the upper side of the breaker
Functionin
g but weak hammering or low
hammering speed
1.
Low rate of oil flow from power
source
2. Pressure in relief valve in power
source is set too low
3. Control valve does not function
properly
4. Back pressure is too high
1.
Turn the engine rot
ation rate up and
increase the rate of oil flow (Adjust
oil flow to the necessary rate)
2. Adjust pressure to the range of 140
～210kgf/㎠ (13.7～20.6MPa) *
3. Remove and clean the joint of control
lever and valve body *
4. Use bigger Diameter hose for return
side
Hammering in normal speed, but week
hammering
1.
Low accumulator gas pressure
2. Damage of accumulator diaphragm
1.
Refill Nitrogen
ga
s
40kgf/㎠ (3.9MPa) *
2. Replace diaphragm *
Strong hammering and in high speed
1. High rate of oil flow
1. Turn the engine rotation rate down
to decrease the rate of oil flow
TROUBLE SHOOTING

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(Adjust oil flow to the right range)
An abrupt stop during operation
1.
Cou
plers are not connected
2.
Damage of control valve
1.
Check each connected parts
2.
Replace a control valve *
Oil leakage from control lever
1. Damage, wear or harden of O ring
1. Replace O ring
*
Profuse
Oil leakage from front end
1.
Damage of U cup packing
2. Damage of U cup packing due to the
scratch of piston rod.
1.
Replace U cup packing
*
2. Replace U cup packing, remove the
scratch on piston rod *
Latch is nearly coming off
1. Damage of lock spring
2. Ware of latch
1. Replace lock spring
*
2. Replace latch *
High pressure hose shakes intensely
1. Damage of accumulator diaphra
gm
1. Replace diaphragm
*
Release
the control valve but the breaker
does not stop
1. Foreign substance is caught in the
valve rod
1. Disassemble, clean and adjust *
For items with *, ask Maruzen dealers for service and maintenance.

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EXPLODED VIEW
MODEL BH221

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