F-Serie

Safety and operating instruction

Hydraulic breakers

Valid from serial number

F150 F0150A001
F200 F0200A001
F300 F0300A001
F400 F0400A001
F500 F0500A001
F600 F0600A001
F750 F0750A001
F900 F0900A001
F1000 F1000A001
F1200 F1200A001
F1300 F1300A001
F1500 F1500A001
F1700 F1700A001
F2200 F2200A001
F2600 F2600A001
F2800 F2800A001
F3200 F3200A001
F3600 F3600A001
F4000 F4000A001
F5000 F5000A001

Version 3.0 EN © Franz GmbH | 2019/01

The data specified here only serves as a product description. A conclusion about a certain condition or suitability for a particular application
cannot be derived from the information given here. The information does not absolve the user from making his/her own assessments and
conducting tests. Keep in mind that our products are subject to a natural wear and ageing process.

© All rights reserved by Franz GmbH, including the industrial property rights.
Every power of disposal such as the right to copy and transfer is reserved.

A sample configuration is shown on the front page. The product delivered can thus deviate from the figure.

The original operating manual was prepared in German.

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Contents

Contents
1 General Information ...........................................................................5
1.1 For the operating personnel ..........................................................5
1.2 Liability ..........................................................................................6
1.3 For better understanding of this manual .......................................6
2 Safety................................................................................................... 7
2.1 Intended use .................................................................................7
2.2 Qualification of the personnel........................................................ 7
2.3 Prohibition, warning, mandatory and instruction signs on the
device ...................................................................................................8
2.4 Basic safety instructions................................................................ 8
2.5 Duties of the operator.................................................................. 12
2.6 Personal protective equipment.................................................... 12
3 Scope of delivery..............................................................................13
4 Product description .........................................................................14
4.1 Technical specifications ..............................................................14
4.2 Device description .......................................................................14
4.3 Product identification...................................................................15
5 Transport and storage .....................................................................16
5.1 Manual transportation .................................................................17
5.2 Transportation using a lifting tool ................................................17
5.3 Moving the support frame using the mounted hydraulic breaker 18
5.4 Storage........................................................................................ 19
6 Mounting the hydraulic breaker on the support frame.................20
6.1 Unpacking ...................................................................................20
6.2 Mounting conditions ....................................................................20
6.3 Required tool ...............................................................................20
6.4 Necessary accessories ...............................................................20
6.5 Mounting the hydraulic breaker ...................................................21
6.6 Fitting and removing the plug tool ...............................................23
6.7 Connecting the hydraulic breaker hydraulically........................... 25
7 Commissioning ................................................................................28
7.1 First commissioning; Re-commissioning after a standstill........... 28
8 Operation ..........................................................................................30
8.1 Operating range .........................................................................30
8.2 Site selection ...............................................................................30
8.3 Information regarding the mode of operation ..............................31
8.4 Process flow ................................................................................34
8.5 Underwater operation.................................................................. 35
9 Tool....................................................................................................36
10 Maintenance (DIN EN 31051)........................................................... 37
10.1 Cleaning and servicing ..............................................................37
10.2Inspection and maintenance .......................................................38
10.3Repairs ........................................................................................42
10.4Spare and wear parts..................................................................43

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Contents

11 Removing the hydraulic breaker from the support frame ............44

12 Disposal ............................................................................................46
13 Cause of malfunction and troubleshooting ...................................47
14 Annex ................................................................................................49
14.1 Tool paste ..................................................................................49
14.2 Cecking and charging up nitrogen..............................................50
14.3 Proof of maintenance..................................................................51

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General Information

1 General Information

1.1 For the operating personnel

This operating manual gives you information regarding the safety,
structure, functioning, operation and maintenance of the hydraulic
breakers listed below:

F150 F750 F1700 F5000

F200 F900 F2200
F300 F1000 F2600
F400 F1200 F2800
F500 F1300 F3200
F600 F1500 F4000
This operating manual ensures smooth and safe operation for a long time if
the instructions are observed carefully.

Applicable documents
• Spare parts catalogue including the parts list and drawings
• Technical details regarding the hydraulic breakers

Applicable documentsregarding supplied components(see Annex

• See the parts list for the operating manual and data sheets of the
individual components

Note
NOTE Detailed information regarding the scope of the provided
documentscan be found in the “packing list”

Safekeeping thisoperating manual

The operating manual (including the applicable documents) must be
stored near the hydraulic breaker such that it is always accessible.

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General Information

1.2 Liability
Franz is not liable for any material defect and guarantee claim in case of
damage caused due to improper use and unauthorised interferences not
provided for in this mounting instruction.
Details regarding material defect claims can be found in the General
Terms and Conditions provided by Franz.
Unauthorised structural modifications to the hydraulic breaker are not
permitted for safety reasons. In addition, you cannot make any changes
in the installation (connections among other things).
Parts and components have been specially designed for the hydraulic
breaker. We would also like to specifically draw your attention to the fact
that parts and special equipment that has not been delivered by us, has
also not been approved by us. Installing and/or using such products can
affect the safety.

1.3 For better understanding of this manual

Conventions
Danger!
DANGER
This danger sign indicates an imminent, great danger that, in all
probability, causes severe injuries or even death in some cases if the
dangerous situation is not dealt with properly.

Warning!
WARNING
This danger sign indicates a possible danger that can cause severe
injuries or even death in some cases if the danger situation is not dealt
with properly.

Caution!
CAUTION
This danger sign indicates a potentially dangerous situation that can
cause minor or moderate physical injuries or material damage if such a
situation is not dealt with properly.

Note
NOTE
This sign indicates additional information.

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Safety

2 Safety
The hydraulic breaker has been manufactured in accordance with the
generally accepted norms of technology. Nevertheless, there is danger
to persons or property if you do not observe the following basic safety
instructions and warnings about instructions in this operating manual.
Read this operating manual thoroughly and in its entirety before you
mount the hydraulic breaker and work with it.
Keep the operating manual such that it is always easily accessible to
all users.
Always pass on the hydraulic breaker to a third party together with the
operating manual.

2.1 Intended use

Adhere to the operating conditions and capacities mentioned in the
Technical Details.
The hydraulic breaker is a technical equipment and not meant for private
use.
The intended use also assumes that you have thoroughly read and
understood this operating manual and particularly chapter 2 “Safety”.
Any other use or any use in excess thereof is considered as improper
and thus strictly prohibited. The operator and/or the user of the hydraulic
breaker are responsible for all the damage caused due to improper use.
The hydraulic breaker is not suitable for operation in an explosive
environment and the parameters and information in the mounting
instruction are applicable at sea level.
The following is included under intended use:
• Following all the notes from the mounting instruction,
• Following the requirements, prohibitions and warnings and •
Adhering to the inspection and maintenance intervals.

2.2 Qualification of the personnel

The mounting, commissioning and operation, removal and maintenance
(including maintenance and servicing) require basic mechanical and
hydraulic knowledge and knowledge of the relevant technical terms.
Hence, these jobs may only be carried out by one relevant qualified
person or an trained person under the supervision of a qualified person in
order to ensure operational safety.
A qualified person is someone who can assess the work assigned to him/
her, detect possible dangers and take suitable safety measures based on
his/her professional training, knowledge and experiences and his/her
knowledge about the relevant regulations. A qualified person must adhere
to the relevant technical rules.

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Safety

2.3 Prohibition, warning, mandatory and instruction

signs on the device
The following signs are affixed on the hydraulic breaker (DIN 4844):

Warning about a danger area!

Read the Manual!

States the sound power level in accordance with

EC directive 2000/14/EC.
xxx

Identifies a lubrication point.

Note
NOTE
More prohibition, warning, mandatory and instruction signs of
components may be affixed on the support frame and on attachments
of the support frame. Information regarding the individual prohibition,
warning, mandatory and instruction signs can be found in the relevant
operating manual.

2.4 Basic safety instructions

2.4.1 General instructions

The potential of danger changes due to the interplay of the hydraulic
breaker and the support frame because the hydraulic breaker is mounted
on the support frame.
This operating manual does not replace the operating manual of the
support frame on which the hydraulic breaker is mounted. This operating
manual must be read and followed.
The safety instructions help to prevent personal injury or damage to
property when dealing with the hydraulic breaker and the environment. All
users must read these safety instructions and follow them at all times.
In addition to the operating manual, the universally valid as well as
local regulations regarding accident control, safety at work and rules for
environment protection must be provided and observed.

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Safety

• Follow the instructions about using the hydraulic breaker in the support
frame operating manual.
• Use the hydraulic breaker only if it is in a technically sound condition.
• Repair the defects in the hydraulic breaker immediately. Inform Franz
immediately in case of malfunctions. Do not make any modifications or
re-constructions in the hydraulic breaker, otherwise the declaration of
conformity becomes invalid and the operating permit is terminated.
• Check the hydraulic breaker for visible defects such as cracks in the
casing, screws, covering caps or seals.
• You may not fundamentally modify or re-construct the hydraulic
breaker.
• Use the hydraulic breaker within the range of capacity only, which is
specified in the Technical Details.
• Do not use the hydraulic breaker in explosive environments if there is
no explicit permission for it.
• Close the front panel of the support frame before you start working with
the hydraulic breaker.
• Wear the necessary protective equipment, e.g. protective helmet, ear
muffs, protective clothing among other things as per the requirements.
• Do not wear loose clothing or jewellery that could get caught in the
operating elements or other parts of the support frame.
• Persons who are under the influence of alcohol, drugs or medicines
may not transport, mount, commission, operate or repair the hydraulic
breaker.
• Only ask for standard signs and that too from one person only when
working on the site.
• The minimum age limit for the operating personnel is 18 years.
• Fasten all the loose objects such as tools and remove these objects
from catwalks, levels, etc.
• Ensure that all the safety equipment belonging to the hydraulic breaker
is available, installed properly and is fully functional. You may not
change the position of the safety equipment, handle it or make it
ineffective.
• Ensure that the activated user can be brought into a safe position (e.g.
immediate stop) by using a proper EMERGENCY STOP function.
• Follow the warning and instruction signs attached to the hydraulic
breaker. In addition, ensure that these signs are not removed and that
they are always legible.
• Comply with the prescribed purity level as per ISO 4406 (c) of the
hydraulic pressure medium. You can find information regarding the
purity level in the support frame operating manual.

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Safety

• Take measures to ensure that there are no dangerous situations for

persons and property parameters if the need arises to stop the safety
equipment for commissioning or maintenance work for instance. Follow
the above-mentioned support frame operating manual for this.
Risk of burns!
DANGER
The hydraulic breaker heats up intensely during operation and can get
very hot when in operation and may cause burns.
� Allow the hydraulic breaker to cool down before you touch it.
� Protect yourself with heat-resistant protective clothing e.g. gloves.
� Follow the ISO 13732-1 and EN 982 standards as well.
• The guarantee is applicable solely for the delivered design. •
The guarantee expires in case of incorrect mounting.
• Pay attention to high-voltage lines, underground cables and feed lines
so that they are not damaged during operation. If they are damaged,
measures must be taken immediately such that there is no danger due
to it.
• Do not work with the hydraulic breaker if any persons are present on
the hydraulic breaker.
• Depending on the type of connection, keep in mind the pressure
condition when connecting to the hydraulic system and when separating
from the hydraulic system. The hydraulic system must be operated at
zero pressure in case of an emergency.
• Keep persons and animals away from the sphere of activity of the
hydraulic breaker during all the mounting and maintenance work.
• Never leave the hydraulic breaker unsupervised during the mounting
and maintenance work.
• The hydraulic breaker may not be operated without the safety
equipment and protective caps attached by Franz or those installed by
customers.
• The defective components must only be replaced with the original parts
having the same hydraulic and mechanical data, otherwise the safety
and functioning cannot be maintained.
• All the safety equipment, fastenings as well as hydraulic connections
and lines must be regularly checked for flawless condition.
• In case of injuries, visit a doctor who is knowledgeable about these
injuries.
• Use sufficient respiratory protection in case of lot of dust formation or
dust containing asbestos.

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Safety

For transportation
• Follow the transportation instructions on the packaging.

For mounting and removing

• Follow the instructions of the manufacturer when using mechanical and
hydraulic changing equipment.
• Follow the support frame-specific instructions and the safety
instructions of the support frame manufacturer when mounting without
changing equipment.
• Connect the connections to the support frame at zero pressure before
you mount the hydraulic breaker.
• Only use a proper tool for that.
• Lay the lines such that they are not damaged.
• Ensure before commissioning that all the seals and fasteners at the
ends are fit correctly and are undamaged such that liquids and foreign
bodies cannot enter into the hydraulic breaker.
• Pay attention to utmost cleanliness when mounting so as to avoid
impurities from entering the hydraulic lines, which could lead to wear
and malfunctions in the hydraulic breaker and support frame.

For commissioning
• Ensure that all the hydraulic connections are covered or closed.
Operate a fully installed hydraulic breaker only.

For cleaning
• Close all the openings using suitable protective equipment such that the
cleaning agents do not enter the system.
• Use a suitable cleaning device for cleaning and follow the instructions
regarding the cleaning device.
• Wear protective clothing (e.g. protecting goggles, face mask among
other things) when dealing with compressed air or pressurised water.

For maintenance
• Carry out the prescribed maintenance work at intervals specified in the
operating manual.
• Ensure that no line links, connections and components come off till the
system is under pressure.
• Do not search for leakages with bare hands; the pressure medium can
come out with high pressure which can cause injuries.

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Safety

For disposal
• Dispose of the hydraulic breaker as per the country-specific regulations.
• Dispose of the pressure medium or grease as per the country-specific
regulations.
• Dispose of the pressure medium residues or grease in accordance with
the valid safety data sheets for pressure mediums and grease.
• Consult Franz or your dealer when using biodegradable mediums.

2.5 Duties of the operator

The operator of the hydraulic breaker must train personnel regularly on
the following topics:
• Following and using the operating manual as well as the legal
regulations
• Intended operation of the hydraulic breaker
• Following the instructions of the site management and the operating
instructions of the site operator
• Behaviour in case of an emergency

2.6 Personal protective equipment

The instructions from the regulations, rules, national laws and ordinances
must be adhered to.
Note
NOTE Follow the country-specific rules and regulations as well.

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Scope of delivery

3 Scope of delivery
The following is included in the scope of delivery:
• Hydraulic hammer according to the technical
specification and "order specification"

Note
NOTE
• Check the scope of delivery for completeness.
• Check the scope of delivery for possible transportation damage, also
see chapter “5 Transport and Storage” on page 16.
• Check whether the operating manual is suitable for the hydraulic
breaker.

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Product description

4 Product description

4.1 Technical specifications

See “Technical Details” (Annex)

Note
NOTE
Inform your dealer or Franz, if the Technical Details are not provided
during the delivery.

4.2 Device description

Note
NOTE
A sample design has been shown in the following figure. The delivered
hydraulic breaker can thus deviate from the figure

1 Support for the quick-change 4 Retaining wedges

device
2 Locking pins 5 Hydraulic connection - OUT
3 Tool 6 Hydraulic connection - IN
Figure1: Breaker

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Product description

4.3 Product identification

Information on the identification plate

The meaning of the information on the identification plate is clarified with
the help of the numbered fields from the following figures and the table.

Note
NOTE
The identification plate is attached on the left side on the hydraulic
breaker.

1 2

Franz GmbH
86720 Nördlingen GERMANY

4 TYPE: xxxx
5 SER.NO.: xxxx
6 WEIGHT [kg]: xxxx
7 YEAR: xxxx

2 8 3

Figure 2:Identification plate

Table 1: Information regarding the identification plate

No. Type of information Information or example
1 Manufacturer logo Franz
2 Name and address of the Franz GmbH
manufacturer Würzburger Straße 22
86720 Nördlingen
GERMANY
3 CE mark
4 Model name e.g. F300
5 Serial number e.g.
6 Weight e.g. kg 300
7 Manufacture year e.g. 2009
8
Warning sign e.g. read manual

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Transport and storage

5 Transport and storage

Danger of material damage and personal injuries!
DANGER
The hydraulic breaker can fall down if not transported properly and
cause damage to the hydraulic breaker and/or personal injuries since
the parts could be sharp-edged, heavy, oily, unstable, loose and bulky.
• Ensure a stable position when transporting to the mounting location
and secure the cargo from shifting.
• Use personal protective equipment (e.g. gloves, work shoes,
protective goggles, work clothing, etc.).
• Follow the national laws and regulations for safety at work, health
protection and transportation.

Danger of damage to health!

CAUTION
There is a danger of damage to health when lifting the hydraulic breaker
or tool.
• Use a suitable technique for lifting, putting down and moving or use
suitable lifting tools during manual transportation.

Note
NOTE
Information regarding the weight of your hydraulic breaker can be found
in the Technical Details.

Transportation damage must be notified to Franz or your dealer within a

week of delivery to the following address:

Franz GmbH
Gewerbering 9
86756 Reimlingen
GERMANY

Tel: +49 9081 272 9099

Fax: +49 9081 290 5884
[email protected]
www.franzgroup.de

You must comply with the environmental conditions specified in the

Technical Details for the transportation and storage.

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Transport and storage

5.1 Manual transportation

Danger of material damage and personal injuries!
DANGER
The hydraulic breaker or tool can fall down if not transported properly
and cause damage to the hydraulic breaker or the tool and/or personal
injuries.
• Use the personal protective equipment (e.g. gloves, work shoes,
protective goggles, work clothing, etc.).
• Do not transport the hydraulic breakers on parts which have low
stability, e.g. connecting hoses.

Pay attention to the following points when transporting manually:

• Use a suitable technique for lifting, putting down and moving.
• Use personal protective equipment (e.g. gloves, work shoes, protective
goggles, work clothing, etc.).
• Do not transport the hydraulic breakers on parts which have low
stability, e.g. connecting hoses.

5.2 Transportation using a lifting tool

Bruises and fractures!

WARNING
If the hydraulic breakers fall down, they could cause severe injuries,
e.g. bruises, fractures.
• Use suitable lifting tools for transportation.
• Pay attention to the prescribed position of the lifting straps.

Danger of material damage and personal injuries!

DANGER
The hydraulic breaker can fall down if not transported properly and
cause damage to the hydraulic breaker and/or personal injuries. Parts
of the hydraulic breaker can become disjointed or twisted.
• For transporting, do not fasten the hydraulic breakers on parts which
have low stability, e.g. connecting hoses.
• Ensure that the sling gear does not rest on parts which have low
stability.

Take into consideration the following points during transportation:

• Properties of the load (e.g. weight, centre of gravity, fastening and
suspension points).

• Manner of suspending or lifting the load.

Ensure that the load bearing capacity of the lifting tool is sufficient for
transporting the hydraulic breaker safely.
Use textile sling gears – in accordance with DIN EN 1492-2.

Note
NOTE
Please contact Franz for more information regarding the transportation.

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Transport and storage

� Tighten the lifting strap on the hydraulic breaker as shown in figure 3

and ensure that the lifting strap does not go over the attachments (e.g.
connecting hoses).

Figure 3:Position of the lifting strap

5.3 Moving the support frame using the mounted

hydraulic breaker
Note
NOTE
Follow the instructions in the support frame operating manual when
moving the support frame using the mounted hydraulic breaker.

Transportation on the loading platform

The hydraulic breaker must be positioned flat on the loading platform if
the support frame is being transported by a different vehicle.
The hoses must not get damaged during the transport, e.g. due to
crushing because they are bent to a great extent.

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Transport and storage

5.4 Storage
The hydraulic breaker can be stored for up to six months in the company
as long as the following criteria are met:
• The hydraulic breaker should be stored in the downward direction
perpendicular to the tool so that the existing seals are not damaged due
to the dead weight of the hydraulic breaker.

Danger of material damage and personal injuries!

DANGER
The hydraulic breaker must be secured as per the regulations for
perpendicular storage to prevent it from falling down so that there is no
damage to the hydraulic breaker and/or personal injuries. Parts of the
hydraulic breaker can become disjointed or twisted.
• Secure the hydraulic breaker properly from tipping over.

• Store in dry and well ventilated rooms only and protect it from soil
humidity.
• Cover with a sheet for protecting from dust and dirt.
• Close all connections using closing plugs.
• After opening the transport package, close it again properly for storage
purposes.

Note
NOTE
Consult Franz for storage exceeding six months.

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Mounting the hydraulic breaker on the support frame

6 Mounting the hydraulic breaker on the

support frame

6.1 Unpacking
Dispose of the packaging as per the country-specific regulations.

6.2 Mounting conditions

You must comply with the environmental conditions specified in the
Technical Details for mounting.
The quick-changer must be attached properly to the support frame and
must be functional.

6.3 Required tool

You can mount and remove the hydraulic breaker using commercial tools.

6.4 Necessary accessories

You need the following accessories for mounting the hydraulic breaker on
the support frame:
• Hydraulic hoses (for connections, see Technical Details of the hydraulic
breaker and the support frame operating manual)

Note
NOTE
Contact your dealer for more information regarding the accessories.

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Mounting the hydraulic breaker on the support frame

6.5 Mounting the hydraulic breaker

Note
NOTE
Have a sufficiently big collection container, enough cloth and medium-
binding materials ready to collect or absorb the hydraulic oil coming out.

Danger of material damage and personal injuries!

DANGER
FAn incorrectly mounted hydraulic breaker can cause considerable
damage to property and persons. An incorrectly fastened hydraulic
breaker can move in an uncontrolled manner and damage other
equipment.
• Basic mechanical and hydraulic knowledge is necessary for mounting
the hydraulic breaker. The hydraulic breaker may be mounted only by
qualified personnel (see section “2.2 Qualification of Personnel” on
page 7).
• Ensure that the hydraulic hammer is fastened securely.

Danger due to usage of an incorrect hydraulic breaker

DANGER range!
Mounting an incorrect hydraulic breaker range can lead to uncontrolled
actions and injure persons or damage the hydraulic breaker and / or the
support frame.
• Check whether you are using the correct hydraulic breaker on the
basis of the model name on the identification plate.
• Check the scope of delivery for completeness.
• Check the scope of delivery for possible damage due to
transportation.
• Check whether the operating manual is suitable for the hydraulic
breaker.

1. You must ensure that the surroundings are clean before mounting
and removing so that dirt does not enter the oil circuit. Only use non-
linting fabric or speciality paper for cleaning purposes.
2. Bring the jib of the support frame in an optimal position so as to hold
the hydraulic breaker with the quick-changer.

Note
NOTE
Follow the instructions of the quick-changer manufacturer.

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Mounting the hydraulic breaker on the support frame

3. Hold the hydraulic breaker with the quick-changer

Figure4: Holding the hydraulic breaker

4. Secure the hydraulic breaker on the quick-changer.

Figure5: Securing the hydraulic breaker

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Mounting the hydraulic breaker on the support frame

6.6 Fitting and removing the plug tool

Fitting the plug tool

Version 2:

Figure 6:Fitting the plug tool

1. Loosen the four screws (1).
2. Remove the locking pins (2).
3. Remove the retainer bars (3).
4. Push the tool (4) and pay attention to the correct position of the
fastening through the retaining bars (3).

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Mounting the hydraulic breaker on the support frame

Caution!
CAUTION
Pay attention to the weight of the tool! Transport the tool securely
and use a lifting gear if necessary.
5. Insert the retaining bars (3) and again till the locking pins (2) and
the screw (1).

Removing the tool

Version 2:

Figure 8:Removing the ool

1. Loosen the four screws (1).

2. Remove the locking pins (2).
3. Remove the retainer bars (3).
4. Pull the tool (4).

Caution!
CAUTION
Pay attention to the weight of the plug tool! Transport the tool
securely and use a lifting gear if necessary.
5. Storing the tool safely and securing it against shifting.

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Mounting the hydraulic breaker on the support frame

6.7 Connecting the hydraulic breaker hydraulically

Note
NOTE
Follow the instructions of the support frame manufacturer.

Wear and malfunction!

CAUTION
The cleanliness of the pressure medium influences the cleanliness and
service life of the hydraulic system. Impurities in the pressure medium
lead to wear and malfunction. Particularly, foreign bodies such as filings
in the hydraulic lines can damage the hydraulic system of the support
frame or the hydraulic breaker.
• Pay attention to total cleanliness.
• Fit the connection lines such that they are free of dirt. •
Ensure that the connection lines are clean.
• Ensure that no impurities enter the lines when closing them.
• Ensure that cleaning agents do not enter the hydraulic system. •
Do not use cotton waste or lint cloth for cleaning.
• Do not use hemp as a sealant.

Danger of injury when mounting under pressure!

CAUTION
Ensure that the hydraulic lines and hoses are at zero pressure before
your start connecting otherwise you can get injured or damage the
hydraulic breaker or the hydraulic system.
• Connect the relevant part of the hydraulic system at zero pressure
before you fit the connecting hoses.

Note
NOTE
Pay attention to the parameters of the hydraulic system.
1. Check the parameters of the support frame hydraulic system to
ensure that they correspond to the Technical Details of the hydraulic
breaker. If they do not correspond, the appropriate change must
be made in accordance with the operating manual of the hydraulic
system or the support frame.
2. Connect the relevant part of the hydraulic system to the support frame
at zero pressure.

Damage to the hydraulic breaker!

CAUTION
Hydraulic lines and hoses, which are fitted under voltage, generate
additional mechanical forces during operation which reduces the
service life of the hydraulic breaker and the support frame hydraulic
system.
• Fit the lines and hoses without tensioning.

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Mounting the hydraulic breaker on the support frame

3. Connect all the connections and follow the support frame operating
manual.

Note
NOTE
Pay attention to the different designs of the hydraulic connections of the
hydraulic breaker in the following figures.

IN OUT

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Mounting the hydraulic breaker on the support frame

4. Remove the protective caps of the hydraulic breaker and support

device. Keep them safely since they have to be used again when
closing the connections.
5. Screw the connections of the hydraulic hoses in the hydraulic breaker
and pay attention to the names of the connections.
Input (IN)- (1)
Output (OUT)- (2)
6. Connect the hydraulic hoses to the support frame and follow the
operating manual of the support frame.
7. Ensure that hoses are connected to all the connections or that the
connections are closed using lock screws.
8. Ensure by checking that the pipe fittings are tightened correctly.

Note
NOTE
Mark all the checked fittings, with a permanent marker for instance.

9. Ensure that the pipes and hose lines and every combination of
fittings, couplings or joints with hoses or pipes are checked for their
safe working condition by a technical expert.

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Commissioning

7 Commissioning
Danger of material damage and personal injuries!
DANGER
The commissioning of the hydraulic breaker requires basic mechanical
and hydraulic knowledge as well as knowledge regarding the operation
of the support frame.
The hydraulic breaker may be commissioned only by qualified
personnel (see section “2.2 Qualification of Personnel” on page 7).

7.1 First commissioning; Re-commissioning after a

standstill
Proceed as described in the following sections to operate the hydraulic
breaker.

Heating the hydraulic breaker

� Work carefully if the temperature of the hydraulic breaker is below -
20 ° C so that the hydraulic breaker can heat up slowly,
� Ensure that the temperature range of the pressure medium is optimum
on the support frame; see operating manual of the support frame.

Conduct a leakage test

� Conduct a functional check of the hydraulic breaker by working briefly
with the hydraulic breaker.

Conducting a functional check

� Conduct a functional check of the hydraulic breaker by working briefly
with the hydraulic breaker.

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Commissioning

Refilling the tool paste

� Refill tool paste at the lubrication point (1), take a grease-gun and
operate it tool paste comes out from the bush.

Figure11: Lubrication point

Caution!
CAUTION
Press the working tool against the piston so that the space between the
piston and the working tool does not fill with grease.

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Operation

8 Operation

Danger of material damage and personal injuries!

DANGER
Working with the hydraulic breaker requires basic mechanical and
hydraulic knowledge and knowledge regarding the operation of the
support frame and thorough knowledge of the working of the hydraulic
breaker.
Only qualified personnel may work with the hydraulic breaker (see
section “2.2 Qualification of Personnel” on page 7).

8.1 Operating range

Danger of material damage and personal injuries!
DANGER
The support frame may be come unstable if used beyond the
prescribed operating range, where it would no longer have any stability
and can topple.
Nobody should be present within 10 m of the tool when the hydraulic
breaker is in operation since torn material can fly around.
• Stick to the operating range and follow the operating manual of the
support frame.
• Stop work with the hydraulic breaker immediately if any persons are
present in the operating range.

The hydraulic breaker may be operated in certain areas only; see the
operating manual of the support frame.
The hydraulic breaker must always be within the operator’s field of vision
during operation; therefore, you must always position the support frame
such that the operator always has a free field of vision of the hydraulic
breaker.

8.2 Site selection

The support frame should stand on a smooth firm ground. Extra caution
must be exercised in case of an uneven, sloping or movable sub-surface;
see operating manual of the support frame.

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Operation

8.3 Information regarding the mode of operation

• Use the hydraulic breaker only for removing stones, concrete and other
solid material.
• Use the correct tool and method for the corresponding material when
working, see chapter „9 Tools” on page 36.
• Use a moil point or chisel tool for breaking the material by penetrating
into it.

Figure12: Breaking the material by penetrating

• Use a blunt tool for breaking the material using pressure wave.

Figure13: Breaking the material using a mechanical pressure wave

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Operation

8.3 Information regarding the mode of operation

• Use the hydraulic breaker only for removing stones, concrete and other
solid material.
• Use the correct tool and method for the corresponding material when
working, see chapter „9 Tools” on page 36.
• Use a moil point or chisel tool for breaking the material by penetrating
into it.

Figure12: Breaking the material by penetrating

• Use a blunt tool for breaking the material using pressure wave.

Figure13: Breaking the material using a mechanical pressure wave

31
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Operation

8.3 Information regarding the mode of operation

• Use the hydraulic breaker only for removing stones, concrete and other
solid material.
• Use the correct tool and method for the corresponding material when
working, see chapter „9 Tools” on page 36.
• Use a moil point or chisel tool for breaking the material by penetrating
into it.

Figure12: Breaking the material by penetrating

• Use a blunt tool for breaking the material using pressure wave.

Figure13: Breaking the material using a mechanical pressure wave

31
 Operating manual / Hydraulic breakers

Operation

• Always position the tool perpendicular to the surface to be broken.

Figure14: Positioning the tool perpendicularly

• Avoid minor irregularities on the surface to be broken when positioning
the tool.
• Put correct pressure with the jib. Vibrations can be transferred to the
support frame, which can cause damage to the support frame, in case
of too low or too high pressure of the jib on the hydraulic breaker.

Figure15: Vibrations
• Avoid strokes without load since it may damage the hydraulic breaker.
• Do not use the hydraulic breaker as a ripper or break lever.

Figure16: Do not rip

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Operation

• Do not operate the hydraulic breaker for more than 30 seconds at the
same point without the tool penetrating. It can lead to overheating and
damage the tool tip.
Search for a suitable point where the tool can penetrate, e.g. a weak
spot in the material.
• Do not rotate the support frame such that you take support of the tip.

Figure17: Do not rotate the support frame by the tip

• Keep the hydraulic breaker in a perpendicular position for at least
one minute after every working hour if the hydraulic breaker has been
operated in a horizontal position or upside-down position.
This allows stones to come out from the bush for instance.

Figure18: Perpendicular position due to upside-down position

• Do not operate the hydraulic breaker in case of fully lowered hydraulic
cylinders at the jib.
• Ensure that the support frame (jib, hydraulic lines among other things)
is not touched or damaged when moving the hydraulic breaker.

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Operation

• Do not use the hydraulic breaker as a transportation device including

the lugs.

Figure19: Hydraulic breaker is not a lifting tool

• Do not use the hydraulic breaker as a clearing device to remove
material from the operating range.
• Work very carefully for the first 15 minutes at temperatures below 0 ° C
so that the tool can heat up slowly.
The tool should not be heated more than necessary, e.g. with a welding
torch.
• According to the Technical Details of the dealer or authorised Service,
change the nitrogen filling pressure if the hydraulic oil temperature is
constantly above 70 ° C.
• Always keep the hydraulic breaker vertical if it is idle or is not used for a
long time so as to avoid damage to seals for instance. Do not ram the
hydraulic breaker into the ground.

8.4 Process flow

In this section, working with the hydraulic breaker has been described
using an example.
Working with the hydraulic breaker depends on the support frame and its
operation; therefore, the operation of the support frame must be observed
and hence this example can only be considered as information.

Pre-conditions
• The hydraulic breaker is attached to the quick-changer of the support
frame, see chapter “6 Attaching the hydraulic breaker to the support
frame” on page 20.
• The support frame is standing in the correct position.

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Operation

Work steps
� Start the support frame and execute further work steps for the
operation as per the operating manual.
� Position the tool at the desired position.
� Firmly press on the material to be broken using the hydraulic breaker.
The correct pressure is built if the support frame gives the impression
of becoming lighter.
� Start the hydraulic breaker and follow the instructions in section “8.3
Information regarding the mode of operation” on page 31.
� Maintain the pressure and break the material by penetrating or by
means of pressure waves.
� Change the position of the hydraulic breaker if the material is not
broken within 15 seconds.
� Stop the hydraulic breaker if the material is broken.
� Repeat the preceding work steps till all the material has been broken
and follow the instructions in section “8.3 Information regarding the
mode of operation” on page 31.
� Stop the support frame.

8.5 Underwater operation

The hydraulic breaker must be equipped with the corresponding kit for
performing work under water. For more information, e.g. mounting the
kit, maintenance, etc., please contact your dealer or the Franz Customer
Service.

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Tool

9 Tool
Selecting the correct tool best-suited for a particular application is of great
importance not only with respect to an increase in productivity of the
hydraulic breaker but also with respect to the service life of the tool itself.
The hydraulic breakers are available with a range of specially-designed
tools. Here is a description of the most widely used tools for the
most common jobs; customers can feel free to contact our Technical
Department for special cases in order to find suitable solutions for any
possible problems that may crop up or for specific problems.
The preferences of the user, the type of machine and the special working
conditions can also influence this choice.
The following overview serves as general information.
Table 2: Tool
Chisel tool Moil point tool Blunt tool

Method Method Method

Penetrate and break Penetrate and break Knock and break
Suitable for all kinds of digging or Suitable for fine/medium-concrete Suitable for fine/medium-concrete
narrow trenching on soft/medium demolition or soft, non-stratified demolition or soft, non-stratified
stratified rocks rocks. Secondary breaking of hard rocks. Secondary breaking of hard
and very hard blocks. and very hard blocks.
Examples Examples Examples
• Sandstone and soft • Sandstone and soft • Granite and hard metamorphous
metamorphous stone, metamorphous stone, stone,
• Concrete demolition • • Concrete demolition • • Concrete demolition •
Trenching Trenching Crushing boulders
• Roadwork • Tunnel construction • • Tunnel construction •
• Frozen floor Roadwork Roadwork
• Compacted soil

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Maintenance (DIN EN 31051)

10 Maintenance (DIN EN 31051)

10.1 Cleaning and servicing

Penetrating dirt and fluids lead to faults!

CAUTION
Safe functioning of the hydraulic breaker is thus not ensured because of
that.
• Pay attention to maximum cleanliness when working on the hydraulic
breaker.
• Use a suitable cleaning device and follow the instructions regarding
the cleaning device.

Damage to the surface due to solvents and aggressive

CAUTION cleaning agents!
Aggressive cleaning agents can damage or ruin the seals and the
surface of the hydraulic breaker and thus cause them to age faster.
• Never use solvents or aggressive cleaning agents.
• Use a suitable cleaning device and follow the instructions regarding
the cleaning device.

Damage to the hydraulic system and seals!

CAUTION
The water pressure of a cleaning device can damage the hydraulic
system and seals of the hydraulic breaker. Water displaces the oil from
the hydraulic system and the seals.
• Use a suitable cleaning device and follow the instructions regarding
the cleaning device.

� Close all the openings using suitable protective caps.

� Use a suitable cleaning device to clean the hydraulic breaker and
follow the instructions regarding the cleaning device. When using
damp cloths, the cloth must be made of a non-linting material. For
that, only use water and a mild cleaning agent if necessary and follow
the operating manual of the support frame as well.

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Maintenance (DIN EN 31051)

10.2 Inspection and maintenance

Danger of material damage and personal injuries!

DANGER
The safety instructions in chapter “2 Safety” on page 7 must be
followed.

• Always use the necessary personal protective equipment, safety shoes,

protective gloves, etc.!
• The support frame must be stopped before working on the hydraulic
breaker if the hydraulic breaker is still attached to the jib.
• Safeguard from an inadvertent re-start of the support frame (take out
the key) and attach a corresponding warning sign. Depressurise the
hydraulic system for the hydraulic breaker; see the operating manual of
the support frame or the hydraulic system.

Danger of damage!
DANGER
Incorrect filling quantity and/or unsuitable lubricant (tool paste) causes
damage to the hydraulic breaker!

10.2.2 Establishing pressure relief on the hydraulic system

The hydraulic system can be depressurised with the help of the circuit
diagram, see the operating manual of the support frame or the hydraulic
system.

10.2.3 Log
The inspection and maintenance conducted must be documented
completely, see section “14.2 Proof of maintenance” on page 50.

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Maintenance (DIN EN 31051)

10.2.4 body
Information regarding the maintenance and inspection

Note
NOTE
A sample design has been shown in the following figure. The delivered
hydraulic breaker can thus deviate from the figure.

1 Lubricating nipple
Figure 20:Lubrication point

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Maintenance (DIN EN 31051)

10.2.5 Maintenance and inspection plan

Note
NOTE
Follow the maintenance and inspection instructions of the support
frame; see the operating manual of the support frame.

Wear maintenance
All movable parts are subject to wear, which depends on the operating
time, load factor and the operating conditions. There are a few
recommendations since the operating conditions are varied.

Period Operating hours Abbreviation in the

maintenance and
inspection plan
Semi-diurnal 4 1
Daily 8 2
Once in two weeks 80 3
Every 6 months Approximately 1000 4
Every 12 months Approximately more 5
than 1500

Note
NOTE You must reduce the maintenance interval in case of major stress on
the hydraulic breaker or due to environmental influences (e.g. lot off
dust formation, high humidity).

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Maintenance (DIN EN 31051)

Maintenance and inspection plan

Activity Remark Period
1 2 3 4 5
Lubricating the tool using tool paste Use the tool paste from section 14.1
on the lubricating nipple, figure 11 on “Tool paste” on page 49 only.
page 29 The period must be shortened to 2 X1)
hours if the environment is very dusty.

Checking all side bolts and visible Tighten all the screw fittings if
X1)
screw fittings. necessary.
Checking the tool for wear and Sharpen the tool if necessary or
X1)
cracks. replace it with a new tool.
Checking the hydraulic lines and Replace the hydraulic lines and hoses
X1)
hoses for damage. if necessary.
Checking the play between the tool The clearance may not be greater
holder (bush) and the tool than 5% of the tool, otherwise
immediately ask the dealer or an X1)
authorised service to replace the
bush.
Visual checking for leakages. Existing leakages must be repaired by
the dealer or an authorised service, X1)
e.g. replacing seals.
Checking the tool and the tool holder The tool must be rotated by 180° and
(bush) for traces of wear. replaced by a new one in case of X1)
strong traces of wear and ridges.
Replacing the seals and diaphragms In case of tough conditions and strong
of the nitrogen accumulator loads.
X1)
Replacement must be done by the
dealer or an authorised service.
Replacing the seals and diaphragms In case of normal conditions and
of the nitrogen accumulator normal loads.
X1)
Replacement must be done by the
dealer or an authorised service.
Checking the flow of hydraulic oil Checking must be done by a qualified
through the hydraulic breaker. person and the check must be X1)
documented.
Checking the hydraulic lines and Checking must be done by a qualified
hoses. person and the check must be X1)
documented.
1) Including the following periods

Note
NOTE The hydraulic breaker must be checked regularly during operation for
proper functioning. Inform Tecna immediately in case of malfunctions.

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Maintenance (DIN EN 31051)

10.3 Repairs

Danger of material damage and personal injuries!

DANGER
The safety instructions in chapter “2 Safety” on page 7 must be
followed.

Tecna offers you a comprehensive service offer for repairing the

hydraulic breaker.
� Only use the original spare parts of Franz for repairing the hydraulic
breaker.

Safety instructions for repairing

The hydraulic breaker may be dismantled for repairs only if it is described
in this operating manual.
Defective parts may be replaced by new tested components having a
structure and quality similar to the original equipment.
� Clean the external environment of fittings and devices before
dismantling. Do not use cotton waste for cleaning.
� Close all the openings using protective caps.

10.3.6 Nitrogen charging of the oil nitrogen accumulator

General conditions
For the breaker to operate correctly, the oil nitrogen accumulator must be
charged adequately. The discharged condition of the accumulator is
shown by strong vibrations of the hydraulic breaker’s oil feed hose. It is
recommended that you disassemble the accumulator every 1000 working
hours (six months) and replace the rubber diaphragm even if it appears to
be in a good condition; see maintenance and inspection plan on page 40.
Once the accumulator is discharged, the polyurethane diaphragm must
be replaced under normal conditions, even if the condition appears to be
satisfactory.

Note
NOTE The oil nitrogen accumulator may be replaced by the dealer or an
authorised service only.

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Maintenance (DIN EN 31051)

10.3.7 Replacing hydraulic lines and hoses

Hydraulic lines and hoses must be replaced if the following criteria are
found true during the inspection:
• Damage to the outer layer up to the insert (e.g. chafe marks, cuts or
cracks),
• Outer layer brittleness (crack formation in the tubing),
• Deformation which does not correspond to the natural shape of the
hose line in the depressurised as well as in the pressurised condition
(also see DIN 20066),
• Leakages in the hose, hose line or valve,
• Damage to or deformation of the valve which affects the functioning and
stability of the valve or the hose-valve connection,
• The hose has dislodged from the valve.
• The valve is corroded such that it is affecting the functioning and
stability.
• The installation requirements have not been met (see DIN 20066). •
The duration of storage and use has been exceeded.

10.4 Spare and wear parts

Damage to property and persons due to defective spare

CAUTION parts!
Spare parts which do not meet the technical requirements specified by
Tecna can cause damage to persons and property.
• Use the original spare parts provided by Franz.

Spare parts can be ordered with the help of the spare part drawing and
parts list, see Annex.
� Specify the following data from the identification plate when placing an
order:
– The serial number
� Specify the following data from the parts list: –
The material number
� In addition, specify the following:
– The quantity of the desired spare parts
� The desired mode of dispatch (e.g. parcel, cargo, freight, courier
service, etc.).

The order must be addressed to your dealer with the specification of the
order number.

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Removing the hydraulic breaker from the support frame

11 Removing the hydraulic breaker from

the support frame

Danger of material damage and personal injuries due to

WARNING pressurised equipment.
When operating pressurised and live wire equipment, there is always
a danger of injury due to the emergent hydraulic oil or current passing
through the body.
• Before dismantling, check whether the hydraulic system is at zero
pressure and the electrical drive is idle.

Note
NOTE
Have a sufficiently big collection container, enough cloth and medium-
binding materials ready to collect or absorb the hydraulic oil coming out.

1. Position the hydraulic breaker in a safe position for removal.

2. Connect the connections to the hydraulic breaker at zero pressure;
see the operating manual of the support device.
3. Provide a container for collecting the emergent hydraulic fluid.
4. Fit the hydraulic hoses between the jib and hydraulic breaker
5. Collect the emergent hydraulic fluid in the container provided and
dispose it legally.
6. Close the connections using the corresponding protective caps.
7. Release the hydraulic breaker at the changer.

Figure21: Releasing the hydraulic breaker

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Removing the hydraulic breaker from the support frame

8. Remove the connection of the hydraulic breaker and quick-changer.

Figure22: Removing the connection to the quick-changer (step 1)

Figure23: Removing the connection to the quick-changer (step 2)

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Disposal

12 Disposal
Careless disposal of the hydraulic unit and pressure medium can lead to
environmental pollution.
Therefore, you must observe the following points:
• Dispose of the hydraulic breaker and pressure medium as per the
country-specific regulations.
• The hydraulic breaker does not emit any hazardous substances if it
is used as directed. Hence, there are no negative effects on human
beings and the environment under normal circumstances.
• The hydraulic breaker can be reused mainly with respect to the material
because of the high metal content. An optimum metal recycling can be
achieved by dismantling individual assemblies.

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Cause of malfunction and troubleshooting

13 Cause of malfunction and

troubleshooting
Table of faults
The hydraulic breaker is indifferent to faults if the prescribed operating
conditions, particularly the hydraulic oil - and the lubricant quality, are
complied with.

Table 3: Table of faults

The breaker does not operate
No pressure in the hydraulic Check the hydraulic system on the
system. support frame; see the operating
manual of the support frame.
Hydraulic oil temperature is too Check the hydraulic system on
high. the support frame; see operating
manual of the support frame.
Hydraulic breaker is not connected Connect the hydraulic breaker to
hydraulically. the hydraulic hoses intended for
that.
The breaker operates with reduced power
Pressure is too low in the hydraulic Check the hydraulic system on
system. the support frame and increase
the pressure, see the operating
manual of the support frame.
Hydraulic oil temperature is too Check the hydraulic system on
high. the support frame; see operating
manual of the support frame.
Leakage in hydraulic system Check the hydraulic system and
repair the existing leakages.
Accumulator defect, pressure Get the diaphragm of the
hoses are vibrating strongly. accumulator removed or replaced
from the dealer or an authorised
service.
Oil flow rate is too low. Increase the oil flow rate; see
operating manual of the support
frame.
The breaker is very irregular
Alternating pressure in the Check the hydraulic system on
hydraulic system. the support frame; see operating
manual of the support frame.
Hydraulic oil temperature is too Check the hydraulic system on
high. the support frame; see operating
manual of the support frame.
Leakage in hydraulic system Check the hydraulic system and
repair the existing leakages.

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Cause of malfunction and troubleshooting

Note
NOTE
For more information on troubleshooting, contact your dealer or an
authorised service.
See the operating manual of the support frame in case of faults in the
support frame.

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Annex

14 Annex

14.1 Tool paste

Note
NOTE
Franz recommends the breaker tool grease
Professional Hammer Grease II. In Table 4 are the specification
of hammer grease.
Order Number: F170228

Table 4
NLGI-class 2
Appearance Fine-grained
Colour gold
Thickener Aluminium complex
Nominal operating range, °C
°C –20 °C bis +1000
Nominal operating range, °C ASTM D-217 270 dmm
Dropping point, °C ASTM D-566 >260 °C
Pour point, °C ASTM D-97 -18 °C
Base oil viscosity grade, ISO ASTM D-445 1000 cSt
4 ball wear test,1200 rpm,75°C,40Kg.1h.,mm ASTM D-2266 0,8 mm
4 ball EP Test, weld load , Kg. ASTM D-2783 >250 Kg
Evaporation, 22 h. @ 150°C, % ASTM-D-972 <1%
Resistance in humidity cabinet ASTM-D-1748 >700
Relative density @ 15°C, Kg./m3 ASTM-D-1480 980 Kg/m3

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Annex

14.2 Checking and charging nitrogen

1 4 2 3

Remove the plug (1) of the charging valve.

Connect the charging device (2) (Partnumber: F170229)
Open the gas bottle valve (3). Carefully open the pressure relief valve (4)
Fill the back head according to table A.
Close the pressure relief valve as soon as the desired pressure is reached
Close the charging valve.

F150 until F300

19
Nitrogen filling pressure in bar

18
17 F200
16 F300
15
14
13
12
11
10 F150
9
8
7
6
-20 0 20 40 60 80
(-4) (32) (68) (104) (140) (176)
ambient temperature°C (°F)

F400 until F5000

20
Nitrogen filling pressure in bar

19
18
17
16
15
14
13
12
11
10
-20 0 20 40 60 80
(-4) (32) (68) (104) (140) (176)
ambient temperature°C (°F)

Required pressure in Back Head

when the hammer is cold and without chisel pressure.
at operating temperature 60-70 °C (140-158 °F) and without
pressure of the chisel.

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Annex

Date Operating Work carried out Carried out by name,

hours signature

Version 3.0 EN 51
 Franz GmbH
Gewerbering 9
86756 Reimlingen
GERMANY

Tel: +49 9081 272 9099

Fax: +49 9081 290 5884
[email protected]
www.franzgroup.de

Version 3.0 EN © Franz GmbH | 2018/02