TMG TMG-EPD700 User manual

4-7 TON EXCAVATOR
HYDRAULIC POST POUNDER
PRODUCT MANUAL
v2023.01.10
TMG-EPD700
Please read and understand the product manual completely before assembly
Check against the parts list to make sure all parts are received
Wear proper safety goggles or other protective gears while in assembly
Do not return the product to dealer. They are not equipped to handle your requests.
Missing parts or questions on assembly?
Please call: 1-877-761-2819 or email: [email protected]
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TABLE OF CONTENTS
SAFETY PRECAUTIONS .....................................................................................................03
STANDARD SPECIFICATIONS ...........................................................................................04
CONSTRUCTION & MAIN PARTS ......................................................................................04
POST POUNDER TOOLS ....................................................................................................06
PREPARATION FOR INSTALLATION & OPERATION..........................................................07
OPERATION........................................................................................................................08
REPAIR & INSPECTION......................................................................................................09
INSPECTION & CHARGING (BACK HEAD)..........................................................................11
TROUBLE – SHOOTING GUIDE...........................................................................................13
CUSTOMER’S REPORT.......................................................................................................15
EXPLODED DRAWINGS AND PARTS LIST..........................................................................16
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SAFETY PRECAUTIONS
1. Safety Precautions
1) This manual contains safety, operation, and routine maintenance instructions. It does not contain service disassembly
instructions. If needed, complete service disassembly and assembly instructions are contained in the manual, which can be
ordered from your
Hydraulic Attachments -Post pounder authorized and certified dealer.
2) Post pounder operator and maintenance personnel must always comply with the safety precautions given in this manual and
on the decal and tags attached to the Post driver hammer and the hose.
3) These safety precautions are given for your safety. Review them carefully before operating the post pounder and performing
general maintenance or repairs.
4) Supervising personnel or the owner operator should develop additional precautions relating to the specific work area and
local safety regulations. Place the added precautions in the space provided under local safety regulations.
5) Please read the following warning.
DANGER
Serious injury or death could result from the improper repair or service of this breaker.
Repairs and/or service to this breaker must only be done by an authorized and certified dealer.
2. General Safety Precautions
(1) The post pounder will provide safe and dependable performance of operation in accordance with the instructions given in
this manual. Read and understand this manual and any decals and tags attached to the post pounder before operation.
Failure to do so could result in personal injury or equipment damage.
a) Operate the post pounder in accordance with all laws and regulations which affect you, your equipment and the
work site.
b) Do not operate the post pounder unless you have read the carrier equipment manual and thoroughly understand all
safety, operation and maintenance instructions.
c) Ensure that all maintenance procedures recommended in this manual are completed before using the equipment.
d) The operator must not operate the post pounder or the carrier if any people are within the area where they may be
injured by flying debris or movement of the equipment.
e) Know the limits of your equipment.
f) Establish a training program for all operators to ensure safe operation.
g) Do not operate the post pounder unless thoroughly trained or under the supervision of an instructor.
h) Become familiar with the carrier controls before operating the carrier and the post pounder.
i) While learning to operator the post pounder and carrier, do so at a slow pace. If necessary, set the carrier mode selector
to the slow position.
j) Make sure all controls (levers and pedals) are in the neutral position before starting the carrier.
k) Before leaving the carrier, always lower the boom and ensure the carrier is stable. Never be the machine with the engine
running. Always engage the parking brake.
l) Stop the engine before attempting to make any repairs, adjustments or servicing to either the carrier or the Post driver
hammer.
m) Do not operate the post pounder at oil temperatures above 175˚F/80˚C. Operation at higher temperatures can damage
to the internal components of the Post driver hammer and back-hoe/excavator and will result in reduced Post driver
hammer performance.
n) Do not operate a damaged, leaking, improperly adjusted, or incompletely assembled post pounder.
o) Do not modify this post pounder in any manner.
p) To avoid personal injury or equipment damage, all post pounder repairs, maintenance and service must only be
performed by authorized and properly trained personnel.
q) If you do not understand how to safely operate your post pounder, contact an authorized dealer for assistance.
r) Keep this manual with the post pounder.
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s) Do not operate this equipment if you are taking medication which may affect your mental judgment or physical
performance.
t) Do not operate the equipment if you are under the influence of drugs or alcohol.
u) Remove the post pounder from the carrier during transport.
STANDARD SPECIFICATIONS
Model
Unit
TMG-EPD700
Excavator capacity
Ton
4-7
Operating weight
lb
640
Working flow rate
GPM
9.5-16
Working pressure
PSI
1600-2000
Oil relief pressure
PSI
2465
Domed cup inside diameter
inch
8
Impact rate
bpm
500-900
Chisel shaft diameter
inch
2.68
Hose Diameter
inch
1/2
Back head pressure
PSI
232
• The above specifications are subject to change without prior notice for the quality
CONSTRUCTION & MAIN PARTS
1. Inner Valve Type
Hydraulic power unit
The power source of post driver, Through the reciprocating
motion of the piston rod, the POST POUNDER is struck on the
stake, etc..
Excavator quick connect
More efficient and labor-saving installation on the excavator,
effectively saving the time cost of replacement.
Post pounder
This transfers piston impact power to the objects.
Hydraulic
power unit
Post
pounder
Excavator
quick
connect
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2. Inner Valve Type
Through bolt
Front head, cylinder and back head of Post driver hammer body
are tightly fixed with four through bolts.
Back head
This contains the cushion chamber charged with nitrogen(N2)
gas that compresses during upward strokes of the piston, and
serves to provide maximum absorption of piston recoil, efficiency
storing this energy for the next blow.
Valve
Cylinder control valve is built in the valve housing and controls
piston reciprocation.
Cylinder
The cylinder is the heart of the Post driver hammer containing
hydraulic circuit for 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 Post driver hammer. Upper
bushing prevents shock from the tool
Through bolt
Back head
Valve
Cylinder
Piston
Front head
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POST POUNDER TOOLS
1. Tool Replacement
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 too.
-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 Post driver
hammer.
Ensure that the tool shank is well lubricated before inserting it into the tool holder.
Keep tools well-greased and sheltered from the weather when not in use.
A rusty tool is more likely to suffer fatigue failure.
The standard inner diameter of the bottom portion of the driver chisel is 200mm.
2. Greasing
1) Manual Greasing System
WARNING
Insufficient greasing may cause abnormal wear of front cover and tool, and tool breakage.
Apply grease to grease nipple on front head every 3 hours.
Adapt grease interval and amounts to tool wear rates and working conditions.
NOTICE
Tool shank must be well lubricated before installed in front head.
While greasing, hydraulic breaker must be upright against the tool. To ensure that
grease will penetrate between tool and inner bush.
Tool Pin
Stop Pin
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Recommended Lubricant Greases
MAKER
GREASE
Esso
Beacon Q2
Shell
Retinax AM
Mobil 1
Mobil 1 Grease special
1) The post pounder must be in a vertical position to grease,
with enough down-pressure to push the tool up inside the housing.
2) Grease until clean grease oozes out around the tool and retainer pins.
3) Grease the post pounder after every two hours of continuous use,
or when the tool appears shiny where it rides inside the front head.
CAUTION
Grease often. Failure to lubricate regularly reduces the life of the tool, bushings, and front
head. If the tool becomes dry and shiny during the shift, apply additional grease.
WARNING
Pressing the tool up inside the post pounder prevents excessive grease entering the impact chamber. The excessive grease
will cause a cushioning affect and a lack of post pounder power when the post pounder is fired.
Excessive grease could contaminate the oil and cause seal failure.
PREPARATION FOR INSTALLATION & OPERATION
1. Hydraulic pipe lines for exclusive use.
Operation of the post pounder requires installation of hydraulic pipe lines for exclusive use of the post pounder.
As hydraulic pipe lines vary depending on base machines, the service engineer must first check hydraulic pressure, oil
capacity, pressure loss and other conditions of the base machine before installing hydraulic pipe lines. Use only
genuine parts In case of replacement because hydraulic pipe lines (hoses, pipes and fittings) are made of materials
carefully selected in consideration of durability.
○
STANDING UP
X
DOWN
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OPERATION
1. Operation method
1. Pre-drill a pilot hole if the soil conditions are rocky, frozen, or too difficult to simply drive the post into the ground.
2. Requires another person to position the pile. This person will set the pile at the desired location and grasp the pile securely.
3. After the pile is in position, let the Driver onto the top of the pile, ensuring the pile is inside of the bottom portion of the
driver, and continue lowering the driver until the weight of the Driver is supported by the pile.
After the pile is in position, the person who grasp the pile must leave vehicle as soon as possible.
Don't allow anyone stand under the attachments.
4. Move the vehicle slowly left, right, forward, or backward as needed until the pile is vertical to the ground.
5. The loader arms should be lowered as the pile is driven into the ground.
6. Drive the pile to the desired depth. Raise the post pounder and move on to the next pile.
2. Operation Precautions
IMPORTANT
1. Before leaving the carrier, always lower the boom and insure the carrier is stable.
2. Never leave the machine with the engine running.
3. Always engage the parking brake.
1) Stop operation as soon as hoses vibrate excessively.
Excessive vibration of high and low pressure hoses of the post pounder calls for an instant disassembly and repair.
Contact the nearest service station.
For caution’s sake, check oil leakage at the bank-head.
2) Avoid all blank hammering.
Continuous blank hammering will not only damage front head and loosen and break bolts, but also adversely affect base
machine.
Blank hammering occurs when proper position of the tool is not applied to the post pounder hammer or the tool is used
as a lever. (Sound changes during blank hammering.)
3) Operate the post pounder at proper engine speed.
Driving the pile at the specified engine speed.
Raising engine speed more than necessary does not strengthen the force but increase oil temperature to the detriment of the
pistons and the valves.
4) Do not allow the post pounder to fall to drive the pile.
Dropping the post pounder onto the pile will apply excessive force to the Post driver hammer or the base machine,
causing damage to many parts of the post pounder and the base machine.
Let the driver press the pile to drive it into the ground.
5) Do not lift things with the post pounder.
Lifting materials by hanging wire in the bracket or the Tool not only causes damage to the post pounder but also is
very dangerous when operating.
6) Warm up base machine engine prior to operation
Especially in winter, the base machine engine should be warmed up for five to ten minutes (about oil temperature
30°C~40°C/80°F~105°F) before Post driver hammer operation.
Follow the Instruction Book for the Base Machine for warming-up of the engine.
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7) Do not touch the Tool during post pounder operation.
During post pounder operation, the post pounder parts can reach high temperatures.
8) When operating the post pounder you must use the ear, eye and breathing protection.
9) Greasing danger
With the post pounder mounted on the machine, apply down pressure on the Driver Tool.
And fill cavity with the recommended grease through the marked grease nipple.
10) Always wear the eye protection when removing the stop pin.
Remove the stop pin by doing it in and out with a punch and hammer.
REPAIR & INSPECTION
1. Periodic Maintenance (Every 100 hours)
1) Remove the tool and all grease from the bushing
Do not use a pressure washer, steam or solvents as they damage the seals.
Chuck for chips or cracks inside the housing and on the bushing surfaces.
Cracks and chips could indicate that :
* Lubrication so insufficient
* Grease type is not appropriate
* Blank hammering and side loading is occurring and hammer is being operated improperly.
2) Check wear on Tool Pin
Examine the shoulders and side surface.
If they are worn or deformed, rotate or replace as required.
3) Check wear on chisel holder bushing
Replace tool, bushing or both where the combined wear exceeds 5mm.
Some bushings are grooved to provide even grease distribution.
Replace the bushings when the grooves are worn through.
Excess bushing wear causes tool misalignment to the piston, causing premature Post driver hammer failure.
4) Replace damaged or worn parts
Then wipe all components clean, including the lubrication port.
Hand grease the tool shank and inside the chuck bushings before placing it back into the hammer.
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2. Daily post pounder inspection
Before starting operation, be sure to inspect the post pounder referring to the following table.
Inspection Item
Inspection Point
Remedy
Looseness, missing and
damage bolts and nuts
Through bolts.
Bracket mounting bolts.
Check looseness.
Retighten securely.
Loose of hose fittings, visible
damage to hose and oil leakage
Hydraulic popes for the post driver.
Oil hoses.
Retighten securely.
Replace seriously damaged parts.
Abnormal oil leakage
Connections of Back head and cylinder.
Clearance between front head & Tool.
Consult with local service station for
further inspection.
Abnormal wear and cracks on
tool
Tool
Deformed, burred and worn out tool
should be repaired.
Excessively worn too needs to be
replaced.
Greasing
Grease at start and every 2 or 3hours using
the head grease pump.
Pumping: 5~10 times (Greasing position
and method shown at left)
Grease the front head
Level and contamination of
hydraulic oil
Conditions of the hydraulic oil
Contamination of hydraulic oil varies
with operating conditions, but oil color
tells the level of contamination criteria
for judging contamination is specifically
set by post driver
Missing the rubber plugs and
the snap rings
Rubber Plugs
Snap Rings
A seriously damaged one must be
replaced.
3. Regular post pounder inspection & Maintenance
Regular inspection is essential for keeping the post pounder operating in the best condition.
Consult with the service station for regular inspection and maintenance.
Customers are recommended to contact the local dealer for inspection within six months after delivery.
4. Replacement of the post pounder
The post pounder is deformed by burrs occurring after long-term use. When a post pounder tip is worn out,
The post pounder is liable to slip. Then, sharpen the post pounder tip. Grinding the post pounder tip many times to sharpen the
edge, but it will make the heat-treated hardened with a new post pounder. If the gap between the Driver Pounder and the post
pounder bush becomes large, the piston will fail exactly to hit the upper part of the post pounder, resulting in damage. When the
gap is found to be over 9mm, replace the post pounder bush together with the post pounder.
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■Change Timing of the Driver Pounder Bush (mm)
Model
Wear Limit(mm)
TMG-EPD700
4
INSPECTION AND CHARGING
Nitrogen (N2) Gas at the Back-Head
WARNING
1. Charging gas pressure changes according to the tool condition. Lay down the breaker and let the tool extend fully.
2. Stay clear of the tool while charging the breaker with gas. The tool may be impacted by the piston and forced out abruptly.
3. When the through bolts are changed the N2gas must be discharged with the back head. As it is highly pressurized.
4. Use nitrogen gas only.
5. See “ Conversion table for charging N2gas pressure to the back head.
1. N2-Gas Charging Tools to the Back-Head
①N2-Gas Cylinder ②Adaptor Nut ③Adaptor ④Hose ⑤Gas Charging Kit
Tool Bush
Wear Limit Dimension
Tool
Wear Limit Dimension
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2.
2. Inspection of N2-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 Post driver hammer.
5) If the gas pressure is higher or lower, charge it as described below.
■Charging of N2-Gas into the Back-Head
1) Connect the charging hose(④) to N2-gas cylinder(①) after screwing the bomb adapter (④) onto adapter nut(②) and
installing than to the N2-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 N2-gas cylinder counter clockwise gradually to
charge the Back-Head.
5) When the gas pressure exceeds 10% higher then the specified pressure, close the N2-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 N2-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.
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TROUBLESHOOTING GUIDE
1. Problems in operation
If the post pounder does not work or blow frequency and blow get worse, check following troubleshooting. And then inspect
according to the following order.
Symptom
Cause
Required action
No blow out
1. Excessive back head gas pressure
2. 2. Stop valve (s) closed
3. 3. Lack of hydraulic oil
4. Wrong adjustment of pressure
5. reducing valve
6. Faulty hydraulic hose connection
7. Oil back head infection
1. Re-adjust nitrogen gas pressure
2. Open Stop Valve
3. Fill hydraulic oil
4. Re-adjustment valve
5. Tighten or replace
6. Replace back head O-Ring, Or
cylinder bush stop seal
Low impact power
1. Line leakage or blockage
2. Clogged tank return line filter
3. Lack of hydraulic oil
4. Hydraulic oil contamination, or heat
deterioration
5. Poor main pump performance
6. Back head nitrogen gas low
7. Low flow rate by mis-adjustment
of flow control pressure reduction
valve
8. Tool out of range for blowing position
1. Check lines
2. Wash fitter, or replace
3. Fill hydraulic oil
4. Replace hydraulic oil, rinse and
release oil inside lines
5. Contact authorized service shop
6. Refill nitrogen gas
7. Re-adjust reduction valve
8. Rush down tool by excavator
Irregular impact
1. Low accumulator gas pressure, of
bad accumulator
2. Bad piston or valve sliding surface
3. Piston moves down/up to blank blow
hammer chamber
1. Refill nitrogen gas
2. Call an authorized service man.
3. Rush down tool by excavator
operation
Bad Driver Pounder movement
1. Driver Pounder diameter incorrect
2. Driver Pounder and pin jammed from
Driver Pounder retainer
3. Jammed lower bush and Driver Pounder
4. Deformed Driver Pounder and piston
contact area
1. Replace Driver Pounder with
genuine replacement parts
2. Smoothen rough surface of Driver
Pounder
3. Smoothen rough surface of
lower bush interior
4. Replace Driver Pounder
Oil leakage between front head
and tool
1. Cylinder seal worn
1. Replace seal
Gas leakage
1. O-ring damage in related parts
1. Replace relevant o-ring
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2. Gas Leakage
Trouble
Cause
Remeby
Gas leakage from the top of
charging valve
1. Defective o-ring in charging valve
2. Defective or damaged in charging valve
1. Replace
2. Repair or replace charging valve
Gas leakage between charging
valve and back head
1. Defective o-ring in charging valve
2. Defective valve loose in back head
1. Replace
2. Re-tighten
Gas leakage between cylinder
and back head
1. Defective o-ring back head
1. Replace
Gas leakage from drain plug hole
1. Defective gas seal in seal housing
2. Defective step seal in seal housing
3. Defective of piston and seal housing
1. Replace
2. Replace
3. Repair or replace seal housing and
piston( When repaired replace
packing)
3. Oil Leakage
Even if oil is leaking, there is no use to replacing parts at all times check the following points listed in the chart below.
The user can check the (☞) marked points before calling dealer.
Area of oil leakage
Condition
Cause & Remedies
A
Between the tool and lower bush
1. A large amount of oil is leaking
2. Check if it is coming from oil or grease
1. Seals cam aged
2. Replace
B
Surface of breaker
1. Oil leaking from the hose & flange
adapter portion
1. ☞loose breaker hoses and
Bolts, retighten
C
Valve housing bolts & cap bolts
1. Oil leaking from reassembly of valve
after overhaul
NORMAL:
During assembly from lubrication
oil & anti-rust oil applied
D
Between main valve & surface of
cylinder
1. Oil leaking from reassembly of valve
after overhaul
NORMAL:
- Clean oil
- Check that seal is damaged
- Loosen bolts
- Replace withe new seal
E
Between cylinder and back head
1. Oil leakage
2. Oil leaks again
1. ☞loose tie rod nuts retighten
2. Replace damaged o-ring
F
Between cylinder and front head
1. Oil leakage
1. ☞loose plugs assembly on the
surface or cylinder, retighten
2. Replace damaged seal
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CUSTOMERS’ REPORT
1. Delivery and Installation Card
This is report is for checking that post pounder is correctly delivered and equipped on machine distributor should correctly
draw up this. This is report must be drawn up in typewritten and Informed within 7 days after the date When delivered post
pounder to customer.
■Machine
●Maker / Model : Manufacturer and model name of the carrier
●Operating Weight
●Operating Hours : Actual operating hours at time or Date delivered out post pounder
●Oil Filter – If there is mark “Y” , if not mark “N”
If there is not it or it’s condition is bad, post pounder should be troubled easily.
Therefore please recommend customer to install it in change new one.
●Others : Performance or Condition of Engine and Hydraulic pump.
■Post pounder
●Model & Serial No : Model name and Serial No. of the post pounder
●Operating Pressure : Actual operating pressure
●Relief set Pressure : Actual relief valve setting pressure for post pounder
●Operating Oil Flow : Actual required operating flow
●Gas Pressure : Actual pressure in accumulator or gas chamber
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EXPLODED DRAWINGS AND PAST LIST
1. Main exploded drawings
2. Main parts list
PART NO.
DESCRIPTION
QTY
PART NO.
DESCRIPTION
QTY
1
Driver pounder (Ø68-200mm)
1
5
Up clamping plate
2
2
Bracket welder
1
6
Side bolt M30*250
4
3
Down clamping plate
2
7
Nuts M30
4
4
Hydraulic hoses 1/2*1.8m with
1/2 NPT fitting
2
8
Hydraulic power unit
1
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3. Hydraulic power unit exploded drawings
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4. Hydraulic power unit parts list
PART NO.
DESCRIPTION
QTY
PART NO.
DESCRIPTION
QTY
A1
Back head
1
A19
Valve
1
A2
Charging valve assembly
1
A20
Valve plug
1
A3
O-ring
3
A21
O-ring
1
A4
Cylinder
1
A22
O-ring
1
A5
Seal retainer
1
A23
Valve sleeve
1
A6
O-ring
3
A24
Front Head
1
A7
Plug
3
A25
Grease nipple
1
A8
Gas seal Ø68
1
A26
Tool pin
1
A9
U-packing(Step seal) SPNS 68
2
A27
Stop pin
1
A10
O-ring
2
A29
Stop pin ( bush)
2
A12
Piston
1
A30
Ring bush
1
A13
Dust seal LBI 70*80*6*8
1
A31
Outer bush
1
A14
U-packing ISI 70*80*6
1
A33
Washer
4
A15
U-packing ISI 70*80*6
1
A34
Through bolt M27*570
4
A16
O-ring
2
A35
Through nut 41mm
4
A17
Adapter
2
A36
Air check valve
1
A18
Union cap
2
A37
O-ring
2
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