OPERATOR OVERVIEW GUIDE

FOR THE HYDRAULIC BREAKER

 Presentation

Plates & Decals

Reference Image Content Signs

Hearing protection Head wearing

must be worn ear protection

Consult manual for proper Technical

service procedures Manual

Vacate work area while the breaker A working breaker with

is in operation diagonal slash

Inject grease into the hole Grease

with grease gun periodically Gun

HIGH PRESSURE requires Accumulator,

dis-charging before disassembly Back Head

Caution - the breaker is HOT High Temperature

SAFETY

All mechanical equipment can be hazardous if operated without due care or correct maintenance. Most accidents
during machine operation and maintenance are caused by failure to observe basic safety rules or precautions.

Accidents can often be avoided by recognising potentially hazardous situations before the incident occurs.

Since it is impossible to anticipate every circumstance that might involve a potential hazard, warnings in this
guide and on the machine are not all-inclusive. If procedures, tools, working methods or operating techniques
not specifically recommended by the manufacturer are used, you must satisfy yourself it is safe both for you and
for others. Also ensure the breaker will not be damaged or made unsafe by the chosen method of operation or
maintenance procedure.

Safety is not just a matter of responding to warnings. When working with the breaker, always pay attention to potential
hazards and how to avoid them. Do not work with this attachment until you are sure you can control it. Do not start
any job until you are sure you and those around you will be safe.

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Safety

Work sites can be noisy. Do not rely only on spoken

! WARNING! commands. See the signaling diagram in the
Read the following warning messages carefully. They Operators Manual of the machine.
inform you of hazards and how to avoid them.
If proper precautions are not taken you or others Work Site
could be seriously injured. Work sites can be hazardous. Inspect the site before
working on it.
Operators Manual
Read and understand the Operators Manual. Check for potholes, weak ground, hidden rocks, etc.
Check for utilities (electric cables, gas and water
The machine operator must be thoroughly familiar pipes, etc.). Mark the positions of underground cables
with how to operate and maintain the breaker and and pipes if you will be breaking the ground.
should preferably undergo training on the breaker.
Banks and Trenches
The machine operator must follow the rules and Banked material and trenches can collapse. Do not
recommendations in this manual and the Operators work too close to banks and trenches where there is a
Manual for the machine, but also pay attention danger of collapse.
to any statutory and national regulations or specific
requirements or risks that apply to the work site. Safety Barriers
Unguarded equipment in public places can be
Care and Alertness dangerous. Place barriers around the machine to
Always take care and stay alert when working with signify a safe working area.
the breaker. Always be careful. Always be alert
for hazards. The possibility of a serious or even fatal Flying Chips of Rock
accident is increased when you are under the Protect yourself and the work area against flying chips
influence of alcohol or drugs. of rock. Do not operate the breaker or the machine if
someone is too close.
Clothing
Suitable safety clothing should be worn. Keep windows and doors closed during operation.
Only machines with enclosed cabs may be used for
Use a hard hat, safety glasses, protective shoes and breaker operation. For skid steers, a special
gloves and an approved respirator (dust mask) or application (demolition door) must be fitted when
other protective articles when required. operating.

Training Equipment Limits

You and others can be killed or injured if you perform Operating the breaker beyond its design limits can
unfamiliar operations without practicing them first. cause damage and can also be dangerous - see
Practice away from the job site, in a clear area. Specification section.

Keep other persons away. Do not perform new Do not try to enhance the performance of the breaker
operations until you are sure you can do them safely. by unapproved modifications.

Communication Equipment Condition

Bad communication can cause accidents. Keep people Defective equipment can injure you and others. Do not
around you informed of what you will be doing. If operate equipment which is defective or has missing
working with other personnel, make sure they parts.
understand any verbal or non-verbal signals you will
be using.

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 Safety

Hydraulic Pressure the job and you know how to use it.
Hydraulic oil at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses, Do not use the breaker, or any of its parts, for lifting.
turn off the engine, operate the controls to release Contact an authorised dealer to find out how to lift
pressure trapped in the hoses and wait 10 minutes. with your machine.
During the operation, keep persons away from the
hydraulic hoses. Never leave a lifted breaker, or any other lifted load,
unattended.
Fine jets of hydraulic oil at high pressure can Follow the Lifting Instructions.
penetrate the skin. Do not use your fingers to check
for hydraulic leaks. Do not put your face close to Spare Parts
suspected leaks. Hold a piece of cardboard close to Use only genuine spare parts. Use only genuine tools
the suspected leak then inspect it for signs of with hydraulic breakers.
hydraulic oil. If hydraulic oil has penetrated your skin,
seek medical treatment immediately. The use of non-genuine or counterfeit parts may
damage the breaker.
There might be pressurized oil trapped inside a
breaker even if it is disconnected from the machine. Metal Splinters
Be aware of possible blank firing while greasing or You can be injured by flying splinters when driving
removing and installing breaker tools. metal pins in and out. Use soft faced breaker or drifts
to remove and fit metal pins, such as pivot pins.
Always wear safety glasses.
Operating Conditions

Principle of Installation
The breaker is installed on the machine similarly to a
bucket or other attachment.

The breaker is connected to the machine hydraulics

through a breaker circuit. If the machine is already
Never use your hand when looking for leaks since oil equipped with such a circuit, only suitable hoses and
under high pressure may penetrate your skin. fittings are required. If the machine does not have
a suitable circuit for running the attachment, one
Pressure Accumulators
must be ordered from your dealer. This may require
The breaker may incorporate one or two pressure
more complex installation, including new piping and
accumulators. The accumulators are pressurised
additional valves such as a directional valve and
even when there is no hydraulic pressure to the
pressure relief valve.
breaker.
Attempting to remove or dismantle the accumulators
without first releasing the pressure can cause injury Operating Temperature
or death. Do not try to dismantle pressure The operating temperature is -20C to +80C (-4F to
accumulators, contact an authorised dealer. +176F) for 0060 - 7000. If the temperature is below
this range, breaker and tool require preheating before
Lifting Equipment operation. Operating at too low a temperature can
You can be injured if you use faulty lifting damage the accumulators membrane and tool. During
equipment. operation they will remain warm.
Make sure that the lifting equipment is in good
condition. Make sure that the lifting tackle complies NOTE! The temperature of the hydraulic oil must be
with all local regulations and is suitable for the job. monitored. Correct oil grade and temperature will
Make sure the lifting equipment is strong enough for ensure correct oil viscosity.

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Operating Instructions

Principles of Breaking Special Conditions of Use

To increase the working life of the breaker correct If the breaker is to be used in special conditions such
working method must be adhered to, and the correct as;
tool chosen for the job. There are essentially two ways tunnel application,
of breaking with a hydraulic breaker. foundry cleaning,
underwater operations,
Penetrative Breaking (or Cutting) operations in extremely low or high temperatures,
In this form of breaking, a moil point or chisel tool is use of special hydraulic oils,
forced into the material. This method is most effective other special conditions,
in soft, layered or plastic, low abrasive materials.
or for demolition work...etc, it may require
modifications, special operating techniques, increased
maintenance or special wear items. Contact an
authorised dealer for instructions.

IMPORTANT! The breaker as a standard assembly

must not be used under water. If water fills the space
where the piston strikes the tool, a strong pressure
wave is generated and the breaker may be damaged.

1. Safety First
When parking the carrier, lower the breaker to the
Impact Breaking ground and turn the engine off.
With impact breaking, the material is broken by
transferring very strong mechanical stress waves from Never attach a cable or sling to the breaker to hoist a
the tool into the material. The best possible energy load. Doing so is extremely dangerous.
transfer between the tool and the object is achieved
with a blunt tool. Impact breaking is most effective in Remove the tool before transporting the breaker.
hard, brittle and very abrasive materials. The use of a
point tool in hard material will cause the sharp edge to Keep all people and equipment away from the breaker
wear very quickly. during operation. Rocks flying from the breaker can
cause serious accident.

A safety screen is recommended to protect the

operator from flying chips of rock. Keep windows and
doors closed during operation. Only machines with an
enclosed cab may be used for breaker operation.
Machines of the canopy version (open cab) should not
be used with a breaker.

Do not use the breaker to sweep the ground of debris.

This may damage the breaker and the housing will
Choosing Tools wear quickly.
A selection of standard and special tools are available
to suit every application. The correct type of tool is 2. Prior Inspection
required for optimum possible results and maximum Check there is sufficient hydraulic oil and that it is not
tool life. Choosing the best tool type for an application contaminated.
may require some experimentation. Tool availability Check that hoses, bolts and nuts are secure.
depends on breaker model - contact an authorised Grease the shank part of the tool - see page 13.
dealer for more information.

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 Operating Instructions

3. Attaching the Breaker Do not operate the breaker with the hydraulic
When attaching the breaker, an assistant is required cylinders fully extended or fully retracted. Damage to
who must be instructed by an excavator driver. All the machine may result.
directions, signals etc. must agreed on beforehand.
When operating the breaker, make sure it does not
The breaker should only be attached to an excavator contact the machine or hydraulic lines.
with sufficient load capacity. If the excavator is too
light it may become unstable under load and fall over. Apply the correct feed force on the breaker: Too
much: Stabilizer leg feet are lifted from the ground or
Do not touch any parts when the boom is moving. tracks are completely lifted from the ground. Too little:
Tool does not stay firmly against material to be broken
Check the pressure relief valve on the hydraulic and machine may start to shake.
system.
Keep the tool perpendicular to the object at all times.
Do not run any hydraulic lines through the drivers If the object moves or its surface breaks, correct the
cab. These lines may start to leak or even burst. angle immediately.
During operation, the hydraulic oil becomes very hot.
Never touch the breaker. Do not let the tool strike without resistance. Keep the
feed force on the breaker steady and aligned with the
If the breaker is connected to an attachment bracket, tool during breaking.
special care must be taken to ensure the attachment
bracket does not sustain any damage. It is not usually effective to strike in one spot for more
than 15 seconds at a time. If the object does not
Equipment Limits break, or if the tool does not penetrate, stop the
Keep personnel away from the risk zone when the breaker and change position of the tool. Working too
breaker is in operation. It is the operators long in one spot creates stone dust under the tool
responsibility to determine the risk zone. which dampens the impact effect and produces heat.

If the noise level exceeds 90 dB(A), all workers in the Stop the breaker quickly. Do not allow the breaker to
immediate area, including the driver of the carrier, fire with no pressure on the tool (dry fire / blank fire).
must wear hearing protection. Frequent idle strokes will damage the breaker.

Stop the breaking immediately if any one moves To use the breaker most efficiently concentrate on
into the danger area, which is much larger for breaker the outer edge of the working area moving towards
operation than for excavator operation due to the risk the middle in small steps
of flying rock splinters.
When breaking hard or frozen ground, use the
Check the oil temperature constantly. Temperature benching method. Start by clearing a small area from
of the hydraulic oil must never exceed 80C. If higher the edge. Then continue by breaking material towards
temperatures are measured in the tank, an oil cooler the open area.
must be fitted.
When breaking concrete, hard or frozen ground, never
At temperatures lower than minus 20C, the breaker pry with the tool. The tool may break.
should not be operated with cold hydraulic oil, the
seals in the breaker may be damaged. Warm the Operating
engine up and move the boom around to raise oil The following precautionary measures should always be
temperature before operating the breaker. taken to rule out the risk of accident.

Only approved hydraulic oils should be used. Only operate the hydraulic breaker from the drivers
seat in the excavator cab.

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Operating Instructions

Close the front screen / splinter guard on the drivers 2. Direction of Thrust
cab to avoid injury from flying rock splinters. Thrust should be in line with the tool, which should be
positioned so the breaking direction is as near vertical
Wear ear protection to prevent hearing impairment. as possible. If the direction is oblique, the tool may
Anyone in the immediate vicinity of breaker slip causing tool and piston to be broken or seized.
operations should also wear ear protection. When breaking, ensure machine is in a suitably stable
position.
Switch off the hydraulic breaker immediately if any
one moves into the danger zone, which is a radius
of at least 7 meters around the hydraulic breaker.
Depending on the application greater distances may
have to be observed.

Correct Working Practice

1. Proper Thrust
To break effectively, a proper thrust force must be
applied to the breaker. If thrust is too low, impact energy Precaution for Operation
of the piston may not be sufficient to break rocks. The operator should observe the following instructions;
Breaking force is transferred to the breaker body, arm
and boom resulting in damage of those parts. Stop the operation immediately if hoses vibrate
excessively. Violent pulsations of the high / low
pressure breaker hoses could indicate an accumulator
fault. Check for oil leaks at the hose fitting points
retightening as necessary. Should symptoms persist,
contact the service shop appointed by the dealer in your
territory for repair. An excessive gap between tool and
workpiece between strikes (See below) may indicate
seizure of the tool in the front head. Disassemble
the front head, inspect the components and repair or
replace defective parts.
Conversely, if thrust is excessive or breaking is
performed with boom of the carrier raised as shown
below, the machine may suddenly tip toward the
movement. The breaker body may strike the broken
rocks violently resulting in damage.

Stop as soon as breaking is completed. As soon

as rocks are broken, cease power to the breaker. If idle
striking continues the accumulator may be damaged,
Excessive force as above may also result in vibrations the bolts loosened or broken and also damage may be
being transmitted to the tracks causing damage. caused to the excavator. When a proper thrust is not
applied to the breaker or the tool is used as a lever, the
Care is required to ensure adequate but not excessive state of idle striking will occur. (Idle striking makes a
force is applied to the breaker in operation. higher pitched ringing sound).

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 Operating Instructions

Never use to move rocks. As shown in the picture, do rock, and advance in small steps. This will enable large
not roll or throw down a rock with the end of the tool rocks to be broken easily. Advancing in large steps will
or the side of the bracket using the oil pressure for not generally improve efficiency.
the carriers boom, arm, bucket, swing or travelling
because the bolts of breaker may be broken, the bracket Operate the breaker at a proper engine speed. The
damaged, the tool broken or scuffed, and the boom or breaker works at a typical engine speed for the carrier.
arm damaged. Never travel the machine with the tool in Increasing to the highest rpm level does not increase
a rock. the breaking force but raises the oil temperature which
results in damage to the internal components of the
breaker. To select the optimum engine speed, please
refer to Carrier Operators Manual.

Never use a breaker in or under water or mud

without prior conversion. If water is allowed to
penetrate the percussion chamber, each blow creates a
pressure wave. These pressure waves cause irreparable
damage to the stripper and seals of breaker. Also the
Never lever with the breaker. Never attempt to use
lower percussion piston zone would rust. Water could
the hydraulic breaker as a crowbar. The breaker is not
also penetrate the carriers hydraulic system. In order to
designed for lateral loads. Both breaker and tool will be
avoid damage to the hydraulic breaker, a special kit has
damaged.
been developed for under water operation.

Never use the breaker as a sledge hammer. Before

starting up, rest the breaker on the ground. Never
Never strike the same spot for more than 30 seconds.
attempt to use the breaker and excavator boom as a
If rocks are especially hard avoid continually striking
sledge hammer to break material. This will damage
the same spot for more than 30 seconds. It is better
parts of the carrier.
practice to change target periodically which avoids
raising the oil temperature. This can result in damage to
the accumulator and excessive tool wear.

Never strike with the cylinders of carrier extended

On a hard, large rock, start breaking at the end point. to the end of stroke. Excavator cylinder damage may
(advance). Begin with a target near the end of a large be caused if the breaker is operated with the arm
fully extended.

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Operating Instructions

To Prevent Blank Firing:

NEVER operate the breaker without a tool.

NEVER operate a breaker unless the tool is pressed

against a solid surface.

ALWAYS stop the breaker as soon as the tool breaks

through the material.

Always warm the carrier up in cold conditions. If

the breaker is operating with low oil temperature the
piston & seals are prone to damage. Warm the carrier
up for five to twenty minutes. During this time operate
the hydraulics to move the boom. Oil temperature must
reach min. 0C before operating the breaker. (Please
refer to Carrier Operators Manual).

Never use the breaker for lifting. Any use of the

breaker for lifting is not permissible and can be very
dangerous.

The Effects of Blank Firing

If the breaker is operated without being pressed
against a solid material (known as blank firing) both
the breaker and the tool can be damaged. Damage can
be caused to the breaker by the internal shocks which
develop in the hydraulic components. Blank firing also
causes rapid wear to the tool retainer pin and the tool
itself. Typically, damage is in the form of heavily burred
edges on the tool and retainer pin as shown. Such
damage is usually not repairable and therefore adds
extra (and unnecessary) costs and delays to the job.

Auto-Stop
Blank firing occurs when an operator continues to press
the breaker pedal after the workpiece is completely
broken. Surplus striking power is conveyed directly to
through bolts, tool pin & other components resulting in
damage to these components and other parts.

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 Operating Instructions

The auto-stop mode was introduced to stop operation

after one extra strike only once the piston extends ! WARNING!
beyond its working range. High pressure is routed Feeding hydraulic oil to an extremely cold hydraulic
directly to the return line and operation stops breaker will cause internal stresses in the unit
immediately. resulting in its failure. If the breaker is used without
preheating the hydraulic oil, the breaker seals may
Efficiency of the auto-stop function has been proven fracture and the diaphragm in the high-pressure
through actual operation at job sites. accumulator may tear. (Please observe the excavator
manufacturers regulations.)
Special care must be taken in certain operations
including secondary breaking of smaller objects where Key Points in Tool Usage:
breaking can be completed in 1-2 strikes. Continued Follow these instructions to avoid unnecessary damage
striking becomes a blank firing condition. to the tool and holder bush:

In this case to prevent unnecessary breaker and tool Avoid lifting, twisting and hitting.
damage;
Minimise exposure to water.
Use Blunt type breaker tool.
Avoid damage from striking the breaker casing off
Release the breaker pedal immediately after the hard objects.
object is broken.
Avoid overheating.
Working in High-Temperature Conditions
The temperature of the hydraulic oil must be Removal & Installation of the Breaker
monitored to ensure it does not exceed 80C. If higher
temperatures are measured in the tank, an oil cooler
must be fitted. Only use hydraulic oils of sufficient
! WARNING!
viscosity. In summer and tropical climates, the minimum The assistant must be instructed by the excavator
requirement is a hydraulic oil type ISO VG 68 HV. (Refer operator and all signals and directions agreed upon
to page 13). beforehand.

Working in Low-Temperature Conditions The breaker should only be attached to an excavator

For temperatures down to minus 20C there are no with sufficient load capacity. If the excavator is too
special regulations, other than warming up the hydraulic light, it may become unstable under load and fall over.
oil before operating. This is achieved by:
Do not touch any parts when the boom is moving.
Starting up the excavator motor.
Collect any oil which leaked out and dispose of it
Moving the boom. correctly.

This raises the oil temperature. Once it has risen above Check that the pressure relief valve on the hydraulic
0C, the hydraulic breaker can be started up. Leave the system has been approved by the relevant authorities.
motor and the pumps of the excavator running during
breaker in work. Check that the hydraulic pipe lines which connected
on from the carrier to the breaker.
Please Note:
The hydraulic breaker and excavator do not operate to
full capacity until the oil temperature has reached at
least 60C.

10
Operating Instructions

Do not touch any parts for a while when the hydraulic Travelling Position
oil keeps on being hot. It may cause your hands to be The travelling positions are shown below. Ensure that
burned. the breaker is not too close to the backhoe boom, when
travelling with a backhoe loader.
Never use your fingers to check the alignment of the
bores.

Backhoe Loader with breaker in travelling position

Lower the loader arm and tilt the breaker fully

backwards when travelling with a skid steer.

Remove the Breaker

1. Remove the hydraulic hose connected with the stop
valve on the boom and the breaker.

2. Close off the hose and the stop valve with caps in the
toolbox.

3. Replace the breaker and the bracket by the bucket in

the same order of the bucket replacement. Skid Steer Loader with breaker in travelling position

4. Follow the reverse order when installing the breaker.

Ensure that the breaker is not too close to the cab
window and that it does not point at it when travelling
with an excavator.

Closing

Opening

Opening and closing of the stop

Excavator / Compact excavator with breaker in travelling
valve (Split type)
position

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 Service and Maintenance

Note:
1. Please replace the parts at operating hours or months whichever comes first.
2. * Please replace the parts according to the wear limit guide.
3. ** Check the hose condition and replace if necessary.
4. Hours: Breaker operating hours. (The operating hours are excavators operating hours that include breakers installation and
operating hours.)

2. It is recommended the user stocks wear parts as follows; Breaker tool, Bottom bush and Upper bush, Tool pins / stopper pin / rubber
plug, Hydraulic seals, Through bolts, Hydraulic hoses

3. The above chart is intended as a guideline only and varies according to the carriers condition, the operators skill and the work
environment.

Service Intervals in Special Applications Breaker strikes slowly.

The service interval is considerably shorter in special
applications such as: tunneling, scaling, foundry Risk of cavitation in pumps and in the hydraulic
cleaning, underwater use, etc. In special applications breaker.
contact a dealer for the correct service intervals.
Sticky valves.
Washing the Attachment
When using the breaker, dirt (mud, rock powder, etc.) Filter bypass opens, impurities in the oil are not
can become attached to it. Wash the outside of the removed.
breaker with a steam washer before sending it to the
workshop. Otherwise, dirt can cause difficulties in Oil too thin
disassembly and assembly. Efficiency losses (internal leaks).

IMPORTANT! Plug the pressure and return line before Damage to gaskets and seals, leaks.
washing the product to prevent dirt and water ingress.
Accelerated wearing of parts, because of decreased
Oil & Lubrication lubrication efficiency.
Breakers require the correct viscosity of hydraulic oil &
grease. The table below specifies grades for extremely Breaker strikes irregularly and slowly.
cold or hot weather. Grease the contact faces in the
lower breaker parts between the working tool and the Risk of cavitation in pumps and in the hydraulic
wear bushes. breaker.

Correct Greasing
Hydraulic Oil Grease While greasing, the breaker must be standing upright
High Low NL Gi No. 2 and resting on the tool to ensure that the grease will
Temperature Temperature (265 - 295) penetrate downwards between the tool and the
*Please use bushes. Turn off the engine and wait 10 minutes for the
ISO VG 68 HV ISO VG 46 HV MOS2 grease oil pressure to drop inside the breaker.
(61.2 - 74.8 cst) (41.4 - 51.6 cst) inclusive of
molybdenum IMPORTANT! Do not fill the space between the piston
and the tool with grease. A lower piston seal failure can
Problems due to incorrect hydraulic oil viscosity result and the breaker will subsequently leak oil.
in the breaker: Oil too thick
Difficult start up.

Stiff operation.

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Service and Maintenance

Cartridge Setting
1. Push the cartridge piston cartridge spout grease
about 10mm.
VERY IMPORTANT!
10mm

Push
2. Insert the cartridge and turn clockwise to hand
tightness only.
For on / off hire queries call
0845 60 70 111

For service requirements call

XXXXXXXX

Adjustment & Manual Greasing

For technical assistance meal /
For hire and service enquiries
call TBC
Call 0845 60 70 111
Grease
nipple for
manual
greasing
Not all products are available in all markets. Under our policy of
L continuous improvement, we reserve the right to change
specifications and design without prior notice. The illustrations
Adjuster do not necessarily show the standard version of the breaker.

Grease refilling port

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