Trojan TH Series User manual

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PREFACE
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Thankyouverymuchforpurchasingourproduct.
TROJAN"TH"seriesHydraulicHammerisahigh‐performancemachine,whichis
successfullydevelopedwiththelatesttechnologyandyearsofourexperiences.
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Thismachineisdesignedandmanufacturedtoensuredurabilityevenunderthe
harshestworkingconditions.However,ifitisnotregularlymaintainedorproperly
handled,theperformanceofthemachinewillnotbeabletogivefullplay,the
servicelifeofeachpartwillbeshortened,andfinallytheentiremachinewillbe
damaged.
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Beforeusingthismachine,pleasedoreadcarefullythisUserManual,whichpoints
outthecorrectoperation&maintenance,soastoobtainthebestworking
performance.
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Mostaccidentsarecausedbyfailuretoobservebasicsafetyrules,soaccidentsare
usuallyavoidable.
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Beforeanyoperation,maintenanceorrepairing,pleasereadandunderstandall
safetyrulesandwarnings.Ifthesewarningsareignored,specialdangersmayoccur,
causinginjuryordeathtotheoperatororothers.Thesewarningsaremarkedwitha
""symbolinthismanual.
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Forsomeoperationsthatmaydamagethemachine,thismanualismarkedwith
"Warning".
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Warning!
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Improperoperation,maintenanceorrepairingofthismachinewillbedangerous,
whichmayresultininjuryordeath.
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BeforereadingandunderstandingthisOperatingManual,nooperation,maintenance
orrepairingjobsareallowedtobedoneonthismachine.
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INDEX
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CHAPTER1MAINSPECIFICATIONS‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐4
CHAPTER2STRUCTURE,FEATURES‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐5
CHAPTER3INSTALLATION,DISMANTLING,STORING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐6
3.1INSTALLATION‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
3.2DISMANTLING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
3.3STORING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
CHAPTER4OPERATION,WARNINGS‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐7‐8
4.1BEFORE&AFTER‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
4.2OPERATION‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
4.3WARNINGS‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
CHAPTER5CHISEL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐9
5.1CHISELTYPE‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
5.2CHISEL&CHISELPINSREPLACEMENT‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
5.3CHISELQUALITYASSURANCE‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
CHAPTER6NITROGENGASRECHARGING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐10
6.1N2CHAMBERNITROGENRECHARGING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
6.2ACCUMULATORNITROGENRECHARGING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
CHAPTER7MAINTENANCE‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐11‐12
7.1BOLTS&NUTS‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
7.2N2CHAMBER&ACCUMULATOR‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
7.3HYDRAULICOIL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
7.4CHISEL&SURROUNDINGS‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
7.5LUBRICATION‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
7.6REPLACEWEARINGPARTSREGULARLY‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
CHAPTER8TROUBLESHOOTING‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐13
CHAPTER9PARTLIST‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐14‐18
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CHAPTER1MAINSPECIFICATIONS
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Description  UnitTH‐SSLTH‐35TH‐50TH‐80TH‐120TH‐140TH‐200TH‐300
Operating
Weight
kg15215229537586186117952635
lb3353356508271898189839575809
Weightof
MainBody
Kg86861512104714718461283
lb1901903334631038103818652828
RequiredOil
Flow
l/min25~5025~5040~7050~9080~11080~110120~180180~240
gal/min6.6~13.26.6~13.210.5~18.513~1421~2921~2932~4848~63
Operating
Pressure
bar90~12090~120110~140120~150150~170150~170160~180160~180
psi1280~17061280~17061565~19911707~213442134~24182134~24182276~25602276~2560
ImpactRatebpm600~1100600~1100550~950400~800350~700350~700350~500300~450
Hose
Diameterinch1/2”1/2”1/2”1/2”3/4”3/4”1”11/4”
ToolDiameter
mm53536875100100140155
inch2.0872.0872.6772.9533.9373.9375.5116.102
Applicable
CarrierWeight ton2.5~4.52.5~4.54~76~911~1611~1618~2628~35
Impact
EnergyClassft.lbs35035050011003250325049006500

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CHAPTER2STRUCTURE,FEATURES

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CHAPTER3INSTALLATION,DISMANTLING,STORING
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3.1 INSTALLATION
Hydraulichammerisconnectedtotheexcavatorwithtwooilhosesandtwopins.
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Lowerdowntheexcavatorarmslowly,alignthepinholes,andfixthepinandpinstopper.Operatethebucketcylinder,so
astofixtheotherpin.
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Removetheendcapsofoilhoses,makesurethehosesclean.Connecttothehammeratoneendandtotheexcavator
pipelineattheotherend.Finally,openuptheStopValveontheexcavatorarm.
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3.2 DISMANTLING
ShutofftheStopValveontheexcavatorarm.RemovethetwoOilHosesfromexcavatorpipeline.RemovethetwoPinsfrom
hammershell.ExcavatorArmgoesupslowly,andthentheHammerwillbefree.FastentheEndCapstothehammerand
excavatorpipelinetopreventdirt.
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3.3 STORING
IftheHammernotbeusedtemporarily,pleasekeepitwellasperthefollowinginstructions:
Removethechisel.EmptytheN2chamber,andstrikepistonbacktocylinder.LubricatetheFrontHeadbygrease.
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PlaceHammeroncrossties,coveredbyraincoat;orindoorwarehoused.
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Ifslowingdowntheengine,itwillbemucheasiertoalignthepinholes.
Afterloosingendcapsofoilhoses,pistoncangobackeasily.

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CHAPTER4OPERATION,WARNINGS
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4.1BEFORE&AFTER
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CheckingIfDetailedItems
Bolts&Nuts
Loosing,MissingorDamage
ThroughBolt,SideBolt,AccumulatorBodyBolt,Accumulator
CoverBolt,etc.
Chisel&Surroundings
Missingordamage
Chisel,ChiselPin,StopPin,Inner&OuterBushes,Rubber
Plug,Circlip,etc.
Pipe&Hose
LoosingorLeaking
SteelPipe,RubberHose,Connectors,andtheWholePipeline,
etc.
OilLeakingBetweenChisel&Bush,BackHead&Cylinder,Accumulator&
Cylinder,etc.
LubricationLubricatewithgreaseafterevery2or3workinghours.
HydraulicOil
Clean,Sufficientornot
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(#46HydraulicOilforhotweather)
(#68HydraulicOilforcoldweather)
Ifitishammer’sfirstrunning,pleasechangenewoilwithin
250workinghours,andchangenewoilfilterwithin50
workinghours.Afterthefirstchanging,pleasechangenewoil
within600workinghours,andnewoilfilterwithin100
workinghours.
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4.2OPERATION
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TheChiselshouldbepressedhardandverticallytotheobjecttobebroken.
Steponthepedal,thehammerwillstrike.
Onceobjectisbroken,stopstrikingimmediately.
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Don’tworkcontinuouslyinhotsummer,topreventtoohightemperatureofhydraulicoil.Ifoiltemperaturereaches80
degreescentigrade,muststopworking,untilthetemperaturelowersdown.
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4.3WARNINGS!
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ForbidanyidlerunningoftheHammer.Idle
runningmeans,theHammerstrikeswhilethe
chiselnotyetpressedhardtotheobjectfor
breaking.Itwillcausedamagestochisel,bush,
throughbolt,accumulator,etc.
Don’tstrikethesamepositioncontinuously,
whichwillcauseabnormalwearing&damages.If
strikingthesamepositionformorethan1minute
andtheobjectstillnotbroken,pleasetrystriking
anotherposition.
Don'tusethechiseltomoverockoruseasa
levertopryrock.Itwilldamagethroughbolts,
chisel,bush,etc.
Don’theavilyhittheobject,whichwillcause
excavatordamage.Thecorrectis,slowlypress
thechiselhardtotheobjectandstartstriking.
Don’tlocatetheHammerintowater,whichwill
causedamagesoftheHammer.
Don’tstrikewhenpistonisatthestrokelimit,
otherwise,excavatorwillbedamaged.
Don'tusethehammertoliftorcarryobject,
whichwilldamagethehammerorexcavator.
Iftheoilhosevibratesabnormally,pleasestop
workingimmediatelyandfindpossibleproblems.

9/19
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CHAPTER5CHISELS
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5.1CHISELTYPE
MoilPointtypeChisel
Itisspeciallyusedforquickbreakingveryhardobject,butnotbreakingintopieces.Ifbreakingobjectintopieces,theBlunt
typewillbemoreefficient.
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WedgetypeChisel
ItisusuallyusedforCivilEngineering,suchasTrenching,AsphaltConcreteRoad,etc.,orsplittingRocks.However,ifbreaking
objectintopieces,theBlunttypewillbemoreefficient.
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BlunttypeChisel
ItisusuallyusedforDemolitionWork,suchasbreakingRocks,BouldersandConstructionBuildings,etc.intopiecesquickly.
However,iftheobjectistoohard,theMoilPointtypewillbemoreefficient.
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5.2CHISEL&CHISELPINSREPLACEMENT
CleansurroundingsoftheChiselPins.PlacetheHammerhorizontally,fromtheoppositesideofRubber,hammeroutthe
StopPin,RubberandChiselPinwiththeRoundBar(packedintheToolBox).BeforefixingnewChisel,pleasefirstly
lubricatethegrooveofChiselbyheat‐resistingAlbanyGrease.
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It’llbedifficulttoreplacenewChiseliftheChiselPinisbadlydeformed,thus,every100~500workinghours,please
dismantleandexchangetheChiselPinstodifferentinterfaces,soastoavoidpins’single‐facewornordeformation.Ifthe
BushorChiselPiniswornordeformed,pleasefirstlyrepair.It’sallowedtogrindthedeformedparts.

5.3CHISELQUALITYASSURANCE
Pleaserefertoourwarrantydetails.
RubberStopPin
RoundBar
Hammer
ChiselPin
Chisel
RoundBar

10/19


CHAPTER6NITROGENGASRECHARGING

Usually,NitrogenGashasalreadybeenchargedandpressurehasbeenadjustedbeforeleavingfactory,butitisnecessaryto
checkagainbeforefirstuse.GasPressureshouldbecheckedregularlyeverytwomonths.

6.1N2CHAMBERNITROGENRECHARGING
ScrewoffanticlockwisetheChargingValve’sEndCap,andconnectthe3‐wayValvetotheN2Chamber.ShutofftheOverflow
Valve.KeeptheN2Bottleclosed,andpresstheSwitchof3‐wayValvetocheckthepressure.Ifpressureistoohigh,please
dischargesomeN2viatheOverflowValve.Ifthepressuretoolow,keeppressingtheSwitchof3‐wayValve,meanwhileopen
theN2Bottletochargeuntilproperpressure(around16Bar).ClosetheN2Bottle,andcloseChargingValve’sEndCap.


6.2ACCUMULATORNITROGENRECHARGING
ScrewoffanticlockwisetheEndCap(#9&#11),andconnectthe3‐wayValveto#9position.ShutofftheOverflowValve.Keep
theN2Bottleclosed,presstheSwitchof3‐wayValve,meanwhilelooseanticlockwisetheChargingValve(#12)alittletocheck
thepressure.Ifpressureistoohigh,dischargeitviatheOverflowValve.Ifthepressuretoolow,keeppressingtheSwitchof
3‐wayValve,meanwhileopentheN2Bottletochargeuntilproperpressure(around60Bar).ClosetheN2Bottle,Charging
Valve(#12),andEndCaps(#11&#9).



11/19

CHAPTER7MAINTENANCE

7.1BOLTS&NUTS
Allbolts&nutsshouldbecheckedbeforeeveryusing,pleasefasteninordersaccordingly(Unit:kg.m).
ItemsUnitThroughBoltSideBoltChargingValveAcc.BodyAcc.Cover
TH‐SSLKg.m4010035**
TH‐35Kg.m4010035**
TH‐50Kg.m4010035**
TH‐80Kg.m4014535**
TH‐120Kg.m4017035**
TH‐140Kg.m16018035**
TH‐200Kg.m24028035**
TH‐300Kg.m280300356045
Warnings!
WhenreplacingmorethantwothroughboltsordismantlingtheHammer,pleasefollowthesteps:
Beforeall,emptytheNitrogenintheN2chamber.
Looseallbolts,includingtheboltsnoreplacingneeded.
Fastentheboltsinorders,A→D→B→C.


7.2N2CHAMBER&ACCUMULATOR
(SeeChapter6)

7.3HYDRAULICOIL
PleasechooseNo.68hydraulicoilforColdweatherandNo.46hydraulicoilforhotweather.Oilshouldbeclean&sufficient
duringworking.DirtyoilwillcausedamagestotheHammer.Whenoilleaks,pleasechangesealkitintime.

12/19


7.4CHISEL&SURROUNDINGS
Beforeeveryusing,checkifthechisel,chiselpin&bushareingoodconditions.Checkregularlytheclearancebetweenbush
andchisel,toomuchclearancewillcausepiston&chiselbroken.Ifchiseldiameterabradesmorethan3mm,orbushinner
diameterabradesmorethan6mm,pleasereplacenewones.


7.5LUBRICATION
Lubricatewithgreasebeforeeveryusingorafterevery2or3workinghours.


7.6REPLACEWEARINGPARTSREGULARLY
Pleasereplacewearingpartsintime.WhenbuyingHammers,customersaresuggestedtobuyextrawearingpartsasbelow
forregularreplacement.
ItemReplacement
ChiselAccordingtotheactualworkingconditions
RodPinEvery30daystochangedifferentinterfacestofixthechisel
StopPinEveryfourmonths
RubberCapWorn,missingordamaged.Pleasereplacenewones.
OilSealEverysixmonths
CylinderThroughBolts&NutsEverysixmonths
HammerShellBolts&NutsEverysixmonths
HydraulicHoseEverysixmonths
OuterBushEverythreemonths
InnerBushEveryfourmonths
Allwearingpartsarenotguaranteedinthewarrantypolicy.









13/19


CHAPTER8.TROUBLESHOOTING



ProblemsPossiblecausesSolution
Tooweakstriking1.Enginerotationspeedlow.
2.GaspressuretoolowinN2Chamber.
3.GaspressuretoolowinAccumulator.
4.Setwrongpressure,oroverflowvalvebroken.
5.Chiselbroken.
6.HydraulicOilnotenoughornotclean
1.Regulateit.
2.Checkandrecharge.
3.Checkandrecharge.
4.Checkandregulate.
5.Grindthedamagesofchiselorbushing.
6.Check,addorchangenewoil
Nostriking1.Wrongpressureofoverflowvalve.
2.GaspressuretoohighinN2chamber.
3.Oilleakstochamber.
4.Cylinder,pistonorvalvesdamaged.
1.Regulatetoproperpressure.
2.Regulatetoproperpressure.
3.Replaceoilseal.
4.Repairsurfacebyabrasivepaper.
Unsteadystriking1.GaspressuretoohighinN2chamber.
2.Pressurelowofoverflowvalve.
3.Chiselorbushdamaged.
4.Cylinder,pistonorvalvesdamaged.
1.Regulatetoproperpressure.
2.Regulatetoproperpressure.
3.Grindtorepairthedamagedpart.
4.Repairsurfacebyabrasivepaper.
Nitrogenleaks1.Inletleaks.
2.Airvalveleaks.
3.N2chamberleaks.
4.Dismantletheoil‐returnhose,ifairbubble
existsintheoil,meansairsealdamaged.
1.ReplacebushingOsealring.
2.ReplacevalveOsealring.
3.Fastenthethroughbolts.
4.Replacetheseal.














14/19


TROJAN“TH”SERIESHYDRAULICHAMMERS
PARTLIST


TH‐SSLMainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐15
TH‐35MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐15
TH‐50MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐15
TH‐80MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐16
TH‐120MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐17
TH‐140MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐17
TH‐200MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐18
TH‐300MainBody‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐19


15/19

TH‐SSL,TH‐35,TH‐50MainBodyPartList


16/19

TH‐80MainBodyPartList


17/19

TH‐120,TH‐140MainBodyPartList


18/19

TH‐200MainBodyPartList


19/19

TH‐300MainBodyPartList
