Hydraulic Breaker

Operation & Maintenance

Manual

Inward Valve Type

40
45
53
68
75
80
85
100
125
140(A)
155
165(F)
175
Outward Valve Type
135
135F
150
175F
185F
195
210

The technical specifications are subject to change

without prior notice.
Printing Number：FEBRUARY 2016
 operation＆maintenance manual

□ Foreword
We appreciate your purchasing our hydraulic breakers.

This manual explains the correct handling methods, inspection, repair, operation, assembly and
disassembly in order to use your hydraulic breaker safely and efficiently.

Also, this manual fully illustrates all the information you need to achieve the best performance and
reduce the breakdown of hydraulic breaker.

Before using this hydraulic breaker, be sure to read and fully understand this manual.

If you do not follow this manual, a serious accident will occur.

WARNING

● The operator should read and fully understand this manual before installing,
repairing or operating this hydraulic breaker.

● This manual should be kept near the hydraulic breaker, and those who use or
manage the hydraulic breaker should read it periodically.

● When this hydraulic breaker is used carelessly, a serious accident can occur
such as serious injury or killing a person.

● If this manual is lost or damaged, please contact our dealer in your territory.

-1-
operation＆maintenance manual

□ Foreword
□ Contents
1. Safety Information — — — — — — — — — — — — — — — — — — — — — — — — — 3-4

2. Specification — — — — — — — — — — — — — — — — — — — — — — — — — — — 5

3. Structure and Working principle — — — — —— — — — — — — — — — — — — — 6-13

4. Installation and Removal — — — — — — — — — — — — — — — — — — — — — — 14-18

4-1 Fundamental circuit
4-2 General view
4-3 Installation
4-4 Removal

5. Maintenance — — — — — — — — — — — — — — — — — — — — — — — — — — — 19-38
5-1 Important Reminder to operator
5-2 Safety label
5-3 Moving and lifting
5-4 Maintenance intervals
5-5 Hydraulic oil
5-6 Greasing
5-7 Inspection and charging of nitrogen gas
5-7-1 Back head
5-7-2 Accumulator
5-8 Pressure setting
5-9 Seal inspection
5-10 Wear inspection
5-11 Inspection and replacement of through bolt
5-12 Torque table
5-13 Storage

6. Operation — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 40-45
6-1 Tool installation
6-2 Safety operation
6-3 Function of adjuster
6-3-1 Cylinder adjuster
6-3-2 Valve adjuster

7. Trouble shooting — — — — — — — — — — — — — — — — — — — — — — — — — — 46-47

8. Service tools — — — — — — — — — — — — — — — — — — — — — — — — — — — — 48-50

8-1 Standard service tools
8-2 Nitrogen gas charging kit

9. Tool selection — — — — — — — — — — — — — — — — — — — — — — — — — — — 51-56

9-1 Guide to tool choice
9-2 Tool claim judgement

-2-
 operation＆maintenance manual

1. Safety Information

■ Before operation
Many accidents occur owning to disregarding the basic rule of installation, operation and repair or
by neglecting the inspection before operation.

Before operating or repairing this hydraulic breaker, be sure to read and fully understand the
preventive methods and warnings described on the hydraulic breaker or in this manual.

Safety labels and messages are classified as below so that the user may understand the warnings
on the hydraulic breaker or in this manual.

DANGER
● Indicates an seriously dangerous situation which, if not avoided, will result in death or
serious injury.
● This signal is to be limited to the most extreme situation.

WARNING
● Indicates a potentially dangerous situation which, if not avoided, could result in death or
serious injury.

CAUTION
● Indicates a potentially dangerous situation which, if not avoided, will result in minor injury.

NOTICE
● Signs are used to indicate a statement of company policy directly or indirectly related to the
personnel safety or property protection.

■ Specified works
This hydraulic breaker can be used for breaking, demolishing and drilling in mines, stone breaking
or building engineering work.

WARNING
● Do not use this hydraulic breaker for other works except the specified
works.

■ Wear the protective tools for safety

—Wear the clothes so that your body would not be caught by the projection of the base
machine or the any lever or pulled by the machine.
—Wear the helmet, safety shoes, earplug, etc. If necessary, wear a dustproof mask,
protective glasses and gloves.
—Usually clean the machine and keep a clear environment for working.

-3-
operation＆maintenance manual

WARNING
● Keep the cautions and take a preventive measure for safety.

■ Observance of safety rules in work place

— Observe all the rules, cautions and procedures for safety when the hydraulic breaker is
operated or repaired.
— Fulfill the work according to the signals.

■ Inspection for safety devices

— When the work is stopped or finished, be sure to set the safety lock of operations for the
hydraulic breaker.
— When the operator gets out from the base machine, be sure to put the hydraulic breaker
on the ground and stop the engine of base machine.

■ Be careful of the hydraulic oil pressure

— Before disconnecting or connecting hydraulic hoses, stop the engine of base machine, close
stop valves “IN” and “OUT” connection, then operate the control lever to release pressure
trapped in the hoses and wait ten(10) minutes.

■ Danger from flying chips of rock during hydraulic breaker operation

— Protect yourself and your neighborhood against flying chips of rock.
Do not operate the hydraulic breaker or base machine if someone is too close.
— Keep the base machine’ s cab doors and windows closed during operation.
Windows bars are recommended to protect the windows from flying chips of rock.

-4-
 operation＆maintenance manual

2. Specification

Contents Model 40 45 53 68 75 80 85 100 125 135 135F

kg 53 71 89 156 214 215 282 479 620 850 846
BodyWeight
lbs 117 156 196 343 471 473 620 1054 1364 1870 1861
Totalweight
1277/1308 1653/1847 1680/1880
（Side/Top kg 70/72/102 95/95/129 158/158/185 263/343/361 334/409/450 335/410/451 559/637/733 761/824/957
/1371 /1893 /1930
/Silence）
mm 918 1090 1178 1373 1515 1630 1735 1994 2285 2423 2427
Length(Side)
inch 36.14 42.91 46.38 54.06 59.65 64.17 68.31 78.5 89.96 95.39 95.55
mm 226 265 285 385 385 385 443 443 555 575 575
Width(Side)
inch 8.9 10.43 11.22 15.16 15.16 15.16 17.44 17.44 21.85 22.64 22.64
90-120 90-120 90-120 110-140 120-150 120-150 130-160 150-170 150-170 160-180 160-180
Operating kg/cm
1280-1704 1280-1704 1280-1704 1562-1988 1704-2130 1704-2130 1846-2272 2130-2414 2130-2414 2272-2556 2272-2556
pressure psi
88-117 88-117 88-117 108-137 118-147 118-147 128-157 147-166 147-166 157-177 157-177
Hydraulic l/min 15-25 20-30 25-50 40-70 50-90 50-90 60-100 80-110 90-120 130-150 145-180
flowrange gal/min 4-7 5-8 6.6-13.2 10.5-18.5 13.1-23.6 13.1-23.6 15.8-26.3 21.1-29.1 23.7-31.7 34.3-39.6 38.3-47.6
Impact
bpm 800-1400 700-1200 600-1100 500-900 400-800 400-800 400-800 350-700 350-650 400-800 360-460
frequency
Diameter mm 12.7 12.7 12.7 12.7 12.7 12.7 19.05 19.05 25.4 25.4 25.4
of hose inch 1/2 1/2 1/2 1/2 1/2 1/2 3/4 3/4 1 1 1
Diameter mm 40 45 53 68 75 80 85 100 125 135 135
of Tool inch 1.57 1.77 2.08 2.68 2.95 3.15 3.35 3.94 4.92 5.31 5.31
Suitable
ton 0.8-2.5 1.2-3.0 2.5-4.5 4-7 6-9 6-9 7-14 10-15 15-18 18-25 18-25
Carrier

Contents Model 140 140A 150 155 165 165F 175 175F 185F 195 210
kg 920 956 1092 1313 1442 1590 1960 1850 2430 2663 3550
BodyWeight
lbs 2024 2103 2402 2889 3172 3498 4300 4075 5331 5842 7788
Totalweight
1774/2059 1809/2094 2218/2380 2577/2644 2751/3156 3277/3447 3905/4057
（Side/Top kg 3714/4047/- 4380/4813/- 5043/5168/- 6687/6997/-
/2011 /2046 /2457 /2670 /2916 /2975 /3902
/Silence）
mm 2480 2480 2640 2776 2820 2820 3184 3170 3326 3420 3660
Length(Side)
inch 95.55 95.55 103.94 109.29 111.02 111.02 125.35 124.8 130.94 134.65 144
mm 575 575 665 665 665 665 764 764 764 764 864
Width(Side)
inch 22.64 22.64 26.18 26.18 26.18 26.18 30.08 30.08 30.08 30.08 34.01
160-180 160-180 160-180 160-180 160-180 170-200 180-210 180-220 190-220 190-220 200- 240
Operating kg/cm
2272-2556 2272-2556 2272-2556 2272-2556 2272-2556 2417-2844 2556-2986 2556-3124 2701-3124 2701-3124 2844-3413
pressure psi
157-177 157-177 157-177 157-177 157-177 167-196 177-206 177-217 186-217 186-217 196-235
Hydraulic l/min 120-180 120-180 150-190 180-240 200-260 200-250 200-260 200-260 220-270 220-290 290-350
flowrange gal/min 31.7-47.6 31.7-47.6 39.6-50.2 47.6-63.36 52.8-68.69 52.8-65.79 52.8-68.42 52.8-68.42 58.08-71.28 58.08-76.56 76.56-92.4
Impact
bpm 350-500 350-500 350-700 300-450 250-400 250-380 250-350 250-350 200-250 180-200 150-200
frequency
Diameter mm 25.4 25.4 25.4 31.75 31.75 31.75 31.75 31.75 31.75 31.75 31.75
of hose inch 1 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4
Diameter mm 140 140 150 155 165 165 175 175 185 195 210
of Tool inch 5.51 5.51 5.91 6.1 6.5 6.5 6.89 6.89 7.28 7.68 8.27
Suitable
ton 18-26 18-26 27-35 28-35 30-40 30-40 35-40 35-40 36-45 40-55 60-80
Carrier

-5-
operation＆maintenance manual

3. Structure and Working principle

Model:40/45/53/68/75/80/85/100/125/140(A)/155/165/165F/175 (Inward valve type)

Back head

Valve

Piston

Ring Bush

Rod Pin

Through bolt

Front cover Seal retainer

Cylinder

Front head

Tool

1) Cylinder
This contains the moving pistion which strikes the tool. The seals for both ends of the piston are also
located in the cylinder. The seals for the upper end of the piston are located in a removable seal
retainer while the seals for the lower end of the piston are located in grooves machined directly into
the cylinder.

2) Piston
The piston transfers impact power to the tool, generated by hydraulic power.

-6-
 operation＆maintenance manual

3) Seal retainer
The seal retainer has oil seals to seal Nitrogen(N 2) gas in back head, and to prevent hydraulic oil
leakage.

4) Valve
The valve controls piston reciprocation with hydraulic fluid distribution.

5) Front head assembly

This retains the tool, using the tool pins.
By removing these pins, the tool can be replaced.

6) Ring bush
This guides the tool, Ring Bush limits the uppermost position of the tool.
It is consumable parts, which should be checked for wear limits. If needed, they should be replaced.

7) Tool
This transfers piston impact power to the objects.
We recommend various tool shapes according to working circumstance.

8) Rod pin
This is installed in the front head, and prevents the tool from coming off.

9) Back head assembly

This contains the cushion chamber charged with nitrogen(N2) gas that is compressed during upward
strokes of the piston, and serves to provide maximum absorption of piston recoil, efficiently storing
this energy for the next blow.

10) Through bolts

These are used to assemble the front head, the cylinder and the back head. They have to be
constantly tightened to specified torque. Inspect the bolts for loosening, and re-tighten them weekly.

-7-
operation＆maintenance manual

1) Set Up
The relation between the area(A1) affecting
the pressure from the upper chamber of the
piston and the area (A2) affecting the
pressure from the lower chamber of the
piston is A1>A2 and high pressure always C2
A3
applies to A2. When A1 change from high to A4
A1
low pressure or vice versa, Piston C1 OUT
reciprocates. Inside of back head is change B3

with the high pressure gas and gas energy C1

IN
stored in the up stroke of the C1 effectively
acts on the piston C1 during the impact.
A2

2) Piston Conversion
When piston C1 reaches top dead center, high
pressure oil from valve high-pressure port B3
applies to upper chamber of the piston A1 to
change the piston stroke from upstroke to
impact. At this time the relation between the
area(A3) affecting the pressure from valve
C2
high pressure changes and the area (A4) of A3
the valve change chamber is A4>A3. The high B4

pressure always applies to A4 and valve C2 B5

OUT A1
remains in the upper position.
B3 B1

IN

C1 B2

3) Valve Conversion
When cylinder low pressure port B1 is
connected to cylinder change port B2, the
pressure in valve change port B4 lowers. As
force acting port C2 is the only pressure in
valve high pressure port B3 is closed and
valve low pressure port B5 is opened to the
lower the pressure in the upper chamber of
the piston A1.

-8-
 operation＆maintenance manual

4) Impact
When piston C1 reaches impact point, kinetic C2

energy obtained by piston C1 during the A3

impact stroke is transmitted to the tool for the A4

OUT
impact energy required to hydraulic breaker.
At this time, as high pressure applies only to
the lower chamber of the piston A2, piston IN
C1 starts reversing. Further, as high pressure
applies only to the valve high pressure C1

chamber A3, valve C2 is remaining in the

A2
lower position.

C2
A4
5) Piston Rise B4
When cylinder change port B2 is B5 A1
connected to cylinder lower pressure port OUT

B1, high pressure oil applies to low B3

pressure outlet port valve C2 this time C1

B1
valve low pressure port A1 this time valve IN
B2
low pressure port B5 is closed and valve
high pressure B3 is opened the upper A2

chamber of the piston A1 to rise the

pressure in the lower chamber of the
piston A1.

A1: Piston upper chamber B1: Cylinder low pressure port C1: Piston
A2: Piston lower chamber B2: Cylinder conversion port C2: Valve
A3: Valve high pressure chamber B3: Valve high pressure port
A4: Valve conversion chamber B4: Valve conversion port
B5: Valve low pressure port

-9-
operation＆maintenance manual

Model:135/135F/150/175F/185F/195/210(Outward valve type)

Valve housing Back head

Vale
Accumulator

Rod Pin

Through bolt

Front cover Seal retainer

Cylinder

Piston

Tool

Ring Bush

Front head

1) Cylinder assembly
This contains the moving pistion which strikes the tool. The seals for both ends of the piston are also
located in the cylinder. The seals for the upper end of the piston are located in a removable seal
retainer while the seals for the lower end of the piston are located in grooves machined directly into
the cylinder.

2) Piston
The piston transfers impact power to the tool, generated by hydraulic power.

-10-
 operation＆maintenance manual

3) Seal retainer
The seal retainer has oil seals to seal Nitrogen(N 2) gas in back head, and to prevent hydraulic oil
leakage.
4) Valve housing
This guides the main valve movement.

5) Valve
The valve controls piston reciprocation with hydraulic fluid distribution.

6) Valve adjuster
When the base machine supplies insufficient hydraulic oil to hydraulic breaker, this valve adjuster can
obtain the rated working pressure by reducing number of blows, and in the reverse, when excessive
oil flow flow from base machine, the increasing number of blows, by this valve adjuster, can keep the
rated working pressure.

7) Cylinder adjuster
Turn the setting screw clockwise to decrease blows rate of hydraulic breaker, counterclockwise to
increase blows rate of hydraulic breaker.

8) Accumulator assembly
The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic
fluid under pressure.
In a hydraulic circuit, minor variations or lags in pump output that might to cause unsteady or irregular
operation , which can be made up from the supply of pressurized oil in the accumulator.
Accumulator is solidly constructed to resist high operating pressure.

9) Front head assembly

This retains the tool, using the tool pins.
By removing these pins, the tool can be changed.

10) Ring bush

This guides the tool, ring bush limits the uppermost position of the tool.
It is consumable parts, which should be checked for wear limits. If needed, they should be replaced.

11) Tool
This transfers piston impact power to the objects.
We recommend various tool shapes according to working circumstance.

12) Rod pin

This is installed on the front head, and prevents the tool from coming off.

13) Back head assembly

This contains the cushion chamber charged with nitrogen(N2) gas that is compressed during upward
strokes of the piston, and serves to provide maximum absorption of piston recoil, efficiently storing
this energy for the next blow.

14) Through bolts

These are used to assemble the front head, the cylinder and the back head. They have to be
constantly tightened to specified torque. Inspect the bolts for loosening, and re-tighten them weekly.

-11-
operation＆maintenance manual

1) Set Up
IN
Chambers C3, C2 always maintain low OUT

pressure, because they are connected to the

output line. Chambers V3,V1,C1 and C3
V3
accumulator always maintain high pressure, A2

because they are connected to the input line.

A4
Chamber V2 pressure is changed to low C3

pressure or high pressure depending on A3 C2

piston position.
V2
C1
A1
V1

Accumulator

2) Piston Rise
Oil enters to “IN” port, and begins to Piston Rise
accumulate force to raise piston, hydraulic
force is applied on A1 of piston lower flange,
and piston begins to rise.
When the piston begins to rise, oil from C4
chamber returns to the output line through the IN

control valve. OUT

A2
V3

A4 C3

A3
C2

V2 A1

C1
V1

3) Valve Rise
When piston rises to around upper limits, A1
of piston lower flange reaches chamber C2,
and the back head nitrogen(N 2 ) gas is
compressed.
At this time, oil from chamber C2 goes to
Valve Rise
chamber V2.
A3 area is larger than A4 area, but applied
pressure of area A3 is the same as applied
pressure of A4.
Therefore, the valve begins to rise, because of
the area difference between A4 and A3.

-12-
 operation＆maintenance manual

4) Piston Descent
When the valve reaches the upper limits,
chamber C4 becomes high pressure area,
because oil from the working pump goes to IN
chamber C2, through the control valve holes. OUT

A2 area is larger than A1 area, but pressure

A2
is applied to A1. C4

V3
Therefore, the piston begins to descend,
because of the area difference between A2
A4 C3
and A1.
At this time, piston descent speed is A3

accelerated by compressed nitrogen (N2) gas

pressure and piston weight. V2 A1
C2

Piston Descent

IN
OUT
5) Impact
Chamber V2 is changed in low pressure as C4
V3
chamber C2 is connected with C3 during piston A2

descent. But V3 is always high pressure. A4

Therefore, the valve begins to descend. C3
A3

C2

V2

A1
C1
6) Continuous Strike
After the piston strikes the tool, the status of all
circuits are changed to “Piston Raising” .
The piston begins to raise via status flowing
into “IN” port, and the cycle is repeated again.

lmpact

-13-
operation＆maintenance manual

4. Installation and Removal

4-1. Fundamental circuit

During installing the hydraulic lines on base machine, it is important to know the fundamental circuit to
which the piping belongs. Then the piping can be connected correctly, properly and quickly.

Stop valve
out
in

Relief valve

Hydraulic breaker Hydraulic breaker control valve

Service port

M.C.V

Pump

E/G

Hyd,tank
(Fig.4-1)

Fig.4-1 is shown the one of simplest hydraulic circuit in case of installation a service port into the main
control valve of base machine.

NOTICE
● If the piping method is different with Fig.4-1, consult us or attachment
m an u f a c t ur e r.

-14-
 operation＆maintenance manual

4-2. General view

NOTICE
● Check the piping lines for correctness, such as pressure, flow or pressure
loss, if the hydraulic pipe are installed in the base machine.
● A pressure control valve has to be installed, if there is no pressure control
valve on the main control valve of base machine.

Standard view of installation is as shown in Fig. 4-2

Stop valve

Hydraulic breaker Hydraulic breaker

ON/OFF switch

Hydraulic breaker control valve

Input Line (Pressure Line)

Output Line (Return Line)

(Fig.4-2)

-15-
operation＆maintenance manual

4-3. Installation

CAUTION
● Never Insert your hand or fingers into the pin hole.

WARNING
● While aligning the arm hole, or moving the bucket, make sure that there
are no person in the vicinity of arm or bucket of base machine.
● It is dangerous to move the base machine suddenly during installation.
● Wear the safety shoes to protect feet.

NOTICE
● Be careful so that dust may not enter the hydraulic breaker and base machine.
● Install or remove the hydraulic breaker on horizontal ground without mud or dust.
1) Set the hydraulic breaker on horizontal ground.
2) Remove the bucket from the base machine after disassembling the two pins.

NOTICE
● If the bucket cylinder is retracted,
the installation will be easier.

3) Move the base machine in the vicinity of

hydraulic breaker, and align the pin hole of arm
with the pin hole of hydraulic breaker, and then,
insert the pins. (4-3-1)
4) After the arm pin is inserted, lift the boom, insert
the hydraulic breaker on the wood blocks like
4-3-3. Extend the bucket cylinder, fit it to the
bucket link’s hole and insert the pins.
5) Install the stop rings, align the bolt holes and
insert the bolts, mutually lock double nuts.

NOTICE
● If the stop rings are secured with (4-3-2)
one nut only, the service life of the
bolt may be shortened or the bolt
may be loosened out very quickly.
6) Stop the engine of the base machine, turn off
the main switch and discharge the air pressure
in the hydraulic oil tank.
7) Remove the union caps from the hydraulic
breaker pipe of the arm end, and connect the (4-3-3)
hoses after disassembling the hose plug.

-16-
 operation＆maintenance manual

NOTICE
● Do not allow the oil to drop onto the
ground.
● Store the removed union cap and hose plug
in the tool box.
● When installing or removing the oil hose
and union cap, clean them fully to prevent
the dust and mud from entering he
hydraulic breaker or the base machine.
8) Connect the hoses to stop valve at both sides of arm.
9) Turn on the engine of the base machine, left the boom,
operate the bucket cylinder and check if the hose of (4-3-4)
hydraulic breaker is connected correctly.
10) Start to warm up the base machine.

HYD’Hose SPEC
Hose
Diam Working
Model Length Pressure
eter (mm)
(inch) (Kg/cm2)

40/45/53
/68/75/80 1/2" 1450 150

85/100 3/4" 1850 170

Cap
125/135(side)/140(A)(side) 1" 2200 180 Plug
135(top/silence)/140(A)(top/silence) 1" 2300 180
135F/150/155 1" 2500 180
155 1 1/4" 2600 180
165/165F 1 1/4" 2800 200 (4-3-5)
175/175F/185F/195/210 1 1/4" 3000 240

NOTICE
● Warm up the base machine by idling for 5
ON OFF
minutes after starting the engine.
● Move the boom and arm for approx. 5 minutes
after warming up operation to raise the
hydraulic oil temperature of base machine.
11) Turn the stop valves to “ON” position.

(4-3-6)

CAUTION
● The tool may come off below oil pressure in the pipe line. Do not stand near to the
hydraulc breaker.

-17-
operation＆maintenance manual

4-4 . Removal

CAUTION
● Personal injury can result from dropping pins during removal.

WARNING
● Wear safety shoes to protect feet.

1) Set the hydraulic breaker on clean and horizontal ground.

Lock the packing brake of base machine.
ON OFF

2) Stop the engine.

3) Turn stop valve to “OFF” position.

4) Disconnect hoses from stop valves. Ensure no leakage

occurs from hoses and stop valves. (4-4-1)

5) Apply union cap and plug to hose ends fittings to prevent

contamination.

6) Remove pins fixing fasteners.

Cap
Plug
7) Remove pins.

8) Move operating joystick slightly, to take weight off (4-3-5)

remaining link pin.

9) Lift arm away from hydraulic breaker so that hydraulic

breaker can be carried away, or another attachment mounted
on base machine.

(4-4-3)

NOTICE

● Cover the hydraulic breaker already

removed with sheet, and then store it in
doors. (4-4-4)

-18-
 operation＆maintenance manual

5. Maintenance

- Important Reminder
to operator

PRECAUTIONS DURING USE OF HYDRAULIC BREAKER

BREAKER
Before Operation
.Check the oil level in the tank
.Grease up Chisel
.Check bolts of looseness
.Charge Nitrogen (N2) Gas in Back Head and Accumulator
to meet standard pressure required.

During Operation
.Avoid blank hitting.
.Must place chisel vertically to surface.
.Do not blow more than one minute on same spot.
.Must replace new front cover once the gap between front
cover and chisel is over the maxium Wear allowance.
.Do not operate the breaker when the cylinder on the
excavator is fully extended.

Storage
.When dismounting breaker,be sure to put plugs in.
Foreign matters in piping will be the cause of trouble.
.Discharging Nitrogen(N2).
.Be sure to keep piston in the position of back head side.

-19-
operation＆maintenance manual

5-2. Safety label

STOP Warning Warning

Stop! Personal protective equipment must be worn Read and understand technical manual before
in this area. Consult your supervisor for instruction. servicing this machine.

Caution

◆ Pressurized container!
◆ Do not open without reading the operating
Warning manual or consulting the service personnel!
◆ Use Nitrogen gas only!
Optimum pressure: 55-60 kg/cm2 (at 20℃)

Noise hazard wear approved ear protection in this

area.

GREASE INJECTION

Greasing label Consult manual warning label

-20-
 operation＆maintenance manual

5-3. Moving and lifting

WARNING
● Always use eye-bolts when lifting & moving the hydraulic breaker, after fasten
up to bracket.
● Fasten the ropes to the shackles (four pieces) and lift the hydraulic breaker up.
● Remove the eye-bolts before hydraulic breaker operation.

Model Eye bolt size (mm) Wire Rope Size (mm)

135/135F/140A/150 M24 ∮16

155/165(F)/175(F)/185F/195/210 M30 ∮20

-21-
operation＆maintenance manual

5-4 . Maintenance intervals

NOTICE
● Before hydraulic breaker operation, be sure to check the following points.

■ Every 3 hours
- Apply the grease in front head.
- Check hydraulic oil temperature, piping and hose connections, and working condition.
- Check tightness of fasteners.

■ Every 10 hours, or Daily

- If rough skin on the total and tool pins have been found, it must be removed.
- Check the nitrogen gas pressure in back head.
- Retighten the bracket bolts.

■ Every 50 hours, or Weekly

- Check the clearance between tool and front cover.
- Check hydraulic hoses.
- Retighten the through bolts.

■ Every 1000 hours, or Six(6) months

- Factory inspection by authorized service personal recommended.
- All hydraulic pipe and hose connections.
- Hose interference from carrier movement.
- Conditions of oil filter, accumulator diaphragm, through bolts and tool pins.

■ Every 2000 hours, or Annually

- All hydraulic pipe and hose conncections.
- Hose interference with excavator boom.
- Conditions of oil filter, accumulator diaphragm and through bolts.
- All seals.
- Conditions of piston, front cover, inner bush.

-22-
 operation＆maintenance manual

5-5. Hydraulic oil

■ Recommended hydraulic oil

Normally, any hydraulic oil originally intended for base machine can be used in the hydraulic breaker.
However oil viscosity must be checked timely, because the oil may be heated much more in the
hydraulic breaker works than in normal excarvator works.
When hydraulic breaker is used continuously the oil temperature normalizes at certain levels,
depending on conditions and carrier.
At such temperatures, hydraulic oil viscosity should be 20-40 cST.

NOTICE
● Usually, the hydraulic oil temperature of hydraulic breaker and base
machine must be controlled between 40℃ and 60℃.
● When you operate the hydraulic breaker while the oil temperature exceeds
80℃, you must check the seals.

Hydraulic oil
Maker
ISO VG68 ISOVG46
ESSO Nuto H68 Univis N46
SHELL Tellus oil 68 Tellus oil 46

MOBILE DTE 16 DTE 15

GULF Harmony68 Harmony 46

For hat weather use For cold weather use

-23-
operation＆maintenance manual

■ Replacement of hydraulic oil & oil filter

Contamination of hydraulic oil may result in part damage, not only in hydraulic breaker, but also in
carrier main components. We recommend hydraulic oil and oil filters replacement as shown in the
following table, which is based on 100% hydraulic breaker operation.

Ｆｉｒｓｔ ２５０ ｈｏｕｒｓ

Ｈｙｄｒａｕｌｉｃ ｏｉｌ
Ｅｖｅｒｙ ６００ ｈｏｕｒｓ
Ｂａｓｅｄ ｏｎ １００％ ｈｙｄｒａｕｌｉｃ ｂｒｅａｋｅｒ ｏｐｅｒａｔｉｏｎ
Ｆｉｒｓｔ ５０ ｈｏｕｒｓ
Ｏｉｌ ｆｉｌｔｅｒｓ
Ｅｖｅｒｙ １００ ｈｏｕｒｓ
■ Hydraulic oil viscosity
Hydraulic breaker must not be started if hydraulic oil viscosity exceeds 1000 cST, not operated when
hydraulic oil viscosity falls 15 cST.

Oil viscosity too high

- Start up difficultly.
- Operation stiffness.
- Irregular hydraulic breaker impact.
- Danger of cavitation in pumps and hydraulic breaker.
- Valve sticking.
- If the filter is very contaminated, hydraulic components could be damaged, due to open bypass
valve.

Oil viscosity too low

- Efficiency losses from internal leakage.
- Damage seals, O-rings.
- Accelerate wearing of parts, because of decreased lubrication efficiency.

■ Cooling
Maximum permitted hydraulic oil temperature range in continuous hydraulic breaker use in 50-80
℃(120-175℉), depending on viscosity of oil in the system.
Therefore, a reliable hydraulic oil thermometer is necessary.
If there is no thermometer on the carrier, one must be installed. Hydraulic oil temperature depends
on ambient conditions, carrier cooling system efficiency, and hydraulic breaker use.
When hydraulic breaker is used continuously, it is necessary to have a cooling system with extra
cooling capacity, as compared with normal excavation work.

■ Hydraulic oil temperature

The normal temperature of hydraulic oil operating is -20℃~80℃(-4℉-175℉), If the temperature is
lower than -20℃(-4℉), the hydraulic oil has to be preheated before operation, in order to avoid
breakage of the accumulator diaphragm.
To preheat hydraulic oil, operate the base machine (without running hydraulic breaker), until oil
temperature rises to specified temperature range.
During operation, oil will remain warm.
If hydraulic oil temperature exceeds specified limits, please stop equipment and don’ t restart
operation until oil has cooled to specified operating temperature range.

-24-
 operation＆maintenance manual

5-6. Greasing

WARNING
● Insufficient greasing may cause abnormal wear of front cover and tool, and
tool breakage.

· Apply grease to grease nipple on front head every 3 hours.

· Adopt grease interval and amounts to tool wear rates and working conditions.

WARNING
● Tool shank must be well lubricated
before installed in front head.
● Greasing label

GREASING

NOTICE
● While greasing, hydraulic breaker must
be upright against the tool, to ensure that
grease will penetrate between tool and
inner bush.

Recommended lubricant grease (NIGI NO.2)

Maker Grease

Esso Beacon Q2

Shell Retinax AM

Mobile Mobile Grease special

-25-
operation＆maintenance manual

5-7. Inspection and charging of Nitrogen(N2) gas

5-7-1. Back head

CAUTION
● Do not stand in front of the tool while nitrogen gas is charged in back head.
● The nitrogen gas in back head must be discharged completely when a through
bolt is replaced or a main body is disassembled.

WARNING

● Use nitrogen gas only.

● The temperature of the hydraulic breaker main body must be normal when
inspection or charging of nitrogen gas in back head.

Handle

Charging gauge
Gas hose
Pressure gauge
Handle
O-ring Cap
Adjuster
Charging valve

N2 cylinder

-26-
 operation＆maintenance manual

(1) Connect gas hose to N2 gas cylinder.

(2) Turn the handle of charging gauge counterclockwise before installing the charging gauge.
(3) Install charging gauge to charging valve.(Make sure that O-rings are installed on charging gauge.)
(4) Connect the other end of gas hose to charging gauge.
(5) Slowly turn the handle of charging gauge clockwise to set charging pressure and turn handle of N2 gas
cylinder clockwise.
(6) Turn the handle of charging gauge counterclockwise, and then turn the handle of N2 gas cylinder
counterclockwise to close.

NOTICE
● For N2 gas sealing pressure, refer to Fig. 5-7-2.

(7) Close the cap of charging gauge after gas hose is relieved from charging gauge.
(8) Recheck charging pressure in back head as turning the handle of charging gauge clockwise.

NOTICE
● When nitrogen gas is charged in back head completely by following
procedures (1) through (8), disconnect charging gauge from charging valve of
back head after the handle of charging gauge counterclockwise, but, if need to
adjust the pressure of charging gas in back head by following procedures (9)
through (13) mentioned below.

(9) Disconnect the gas hose from charging gauge.

(10) Install charging gauge on charging valve of back head completely.
(11) When turning the handle of charging gauge clockwise, gas pressure in back head is indicated on
pressure gauge.
(12) If gas pressure is low, perform operations (1) through (8) again, repeat until gas pressure rises
to specified range.
(13) If gas pressure is excessive, slowly turn the adjuster of charging gauge counterclockwise, then
gas pressure leaks from back head. When correct amount of gas pressure is shown, close the
adjuster clockwise.
When gas pressure is excessively high, breaker will not work.
Ensure that gas pressure is at specified range and O-ring in charging gauge is installed.

-27-
operation＆maintenance manual

20

18 40 (A)/
/135/1
5 / 1 0 0/125 / 2 1 0
0/8 195
/ 5 3 / 6 8/75/8 5(F)/185F/
40/45 /165(F)/1 7
16
155
Gas pressure(bar)

14

12

10

0
8
35 F/15
1 35/1

-20 0 20 40 0
Surrounding temperature(℃)
(Fig. 5-7-2)

Model Charging Pressure(Kg/cm2 )

40 16-17
45 16-17
53 16-17
68 16-17
75/80 16-17
85 16-17
100 16-17
125 16-17
135 6-7
135F 9-10
140(A) 16-17
150 6-7
155 16-17
165(F) 16-17
175(F) 16-17
185F 16-17
195 16-17
210 16-17

-28-
 operation＆maintenance manual

5-7-2. Accumulator

CAUTION
● Tighten the accumulator body and accumulator cover before charging the
nitrogen gas in accumulator assembly.

WARNING

● Use nitrogen gas only.

● The temperature of the hydraulic breaker main body must be normal when
inspection or charging nitrogen gas of accumulator.

NOTICE

● Be sure to use a charging gauge for charging the nitrogen gas.

● If the nitrogen gas is charged from gas cylinder without charging gauge, the
diaphragm may be damaged.

Handle

Gas hose
Charging valve Handle
Pressure gauge
Cap
O-ring
Plug
Adjuster

O-ring

O-ring
Adjuster
O-ring
Cap

N2 cylinder

-29-
operation＆maintenance manual

A) Inspection of charging pressure

(1) Turn the handle of charging gauge counterclockwise.
(2) Remove the A plug on the accumulator and charging gauge completely.
(3) Remove the cap of adjuster from accumulator.
(4) Turn the adjuster counterclockwise slowly to indicate accumulator charging pressure.
(5) Remove charging gauge and tighten plug and cap.
(Ensure O-rings must be installed in plug and cap).

B) Charging accumulator with nitrogen gas.

(1) After performing steps same inspection of charging pressure.
(2) Connect gas hose charging gauge and N2 gas cylinder.
(3) Turn the adjuster counterclockwise after removing the cap from adjuster.
(4) Slowly turn handle of N2 gas counterclockwise to charge accumulator with N2 gas charging pressure.
(refer in Fig. 5-7-4)
(5) When accumulator is charged with N2 gas completely, close the adjuster fully.
(6) Turn the handle of N2 gas cylinder clockwise to close.
(7) Loosen adjuster of charging gauge to discharge N2 gas remaining in gas hose.
(8) Remove the gas hose from charging gauge to N2 gas cylinder.
(9) After removing gas hose, adjust the pressure referring to A) Inspection of charging pressure
(10) After charged accumulator with N2 gas, check gas leakage from adjuster, plug hole of accumulator.

/210
/185 F/195
(F)/1 75(F)
60 0/15 5/165
4 0A/15
35F/1
135/1
Gas pressure(bar)

40

20

0
-20 0 20 40 60 80
Surrounding Temperature
(Fig. 5-7-4)

-30-
 operation＆maintenance manual

5-8. Pressure setting

The pressure setting for hydraulic breaker must be lower than the base machine pressure setting in
order to protect the pump of base machine.
Normally, set the pressure for hydraulic breaker about 5-10kg/cm 2 lower than base machine pressure
setting, when the main pressure of base machine is lower than below table.

If hydraulic breaker setting pressure higher than below table:

That will shorten durable of main pump and shorten service life of seals & tool in hydraulic breaker.

If hydraulic breaker setting pressure higher than below table:

Hydraulic breaker performance will be downed.

Recommended setting pressure for hydraulic breaker (Kg/cm 2)

40/45 130~140

53/68 150~160

75/80/85 160~180

100/125 180~200

135/135F/140(A)/150/155/165 220

165F 240

175/175F 250

186F/195 260

210 270

-31-
operation＆maintenance manual

5-9. Seal inspection

WARNING
● Replace seals every 2000 hours of actual operation.

1) If any hydraulic oil leakage from hydraulic breaker is discovered, faulty seals should be replaced.
To figure where seals are bad, refer to following drawings:

Back up ring- O-ring & dust seal- U-packing & Buffer ring-
Worn, distorted worn, deteriorated deformed, worn, distored, perished

2) When bad seal is found, the cause of the damage must be determined and rectified.
When seal is changed, apply grease to seal and seal seat, and hold seal firmly with thumb, index and
middle fingers, as per marking.
Be careful not to break seal through excessive deformation.

-32-
 operation＆maintenance manual

5-10. Wear inspection

5-10-1. Front cover

If the clearance between tool and front cover is too big, it could cause of damage, or breakage of tool
through piston irregular contact.
The following table is shown the wear limit of hydraulic breaker tool and front cover for reference purposes.

Piston
A

Irregular Impact

Front Head
B B

Front Cover (Top & Side) Front Cover (Box-Silence)

Table 1 Front Cover （mm） Front Cover

measure at measure at Reject Inside
Item Model
B A Dia.
1 40 10 40 43 Tool

2 45 10 45 48
3 53 10 53 56
4 68 10 68 72
5 75 10 75 80 Angle of Inclination

6 80 10 80 85
7 85 10 85 90 If the clearance between tool
8 100 10 100 105 and front cover is too big, it
could cause following
9 125 10 125 130
problems:
10 135 10 134.5 140.5
1. It could cause irregular
11 135F 10 135 140 impact and this may
12 140(A) 10 140 146 shorten the life of piston.
13 150 10 150 156 2. It could cause angle of
14 155 10 155 161 inclination and this may
be lead to the breakage
15 165(F) 10 165 172
of tool.
16 175(F) 10 175 182
17 185F 10 185 193
18 195 10 195 203
19 210 10 210 220

-33-
operation＆maintenance manual

5-10-2. Tool Pin

NOTICE
● Change the face of tool pins every 100 to 150 hours of actual operation.
● Replace tool pins every 500 hours of actual operation.

A) When each tool pin is excessively deformed, it is difficult to replace the tool, therefore, after operating
the hydraulic breaker every 100 to 150 hours, change the face of each pin which comes in contact
with the tool (The faces of each pin can be used).

B) When replacing each tool pin, check each parts for wear, breakage, scores, etc., especially. And
remove burrs and swelling on tool pins.

C) Replace tool after grinding the worn parts of front cover and tool pins.

When changing tool pins direction, place tool pins by opposite side.
Remove burrs and swelling with grinder or the like.

When changing tool pins direction,place tool pins

by opposite side.

Remove burrs and swelling

with grinder or the like

-34-
 operation＆maintenance manual

5-11. Inspection and replacement of through bolt

CAUTION

● Discharge completely N2 gas in back head prior to loosen through bolts.

1) Discharge nitrogen (N2) gas in back head completely prior to loosen through bolts.

2) Remove all through bolts, and inspect for presence of any cracks and damages on through bolts.

3) When through bolts are assembled, tighten bolts one turn at a time in diagonal sequence; not each
nut completely all at once turn of times, not completely at once.

4) Use to torque wrench of specificed range.(Refer to torque table)

3 1

2 4

-35-
operation＆maintenance manual

5-12. Torque table

(1) Before starting the hydraulic breaker operation, check all kind of bolts and nuts for tightness
including the through bolts, socket bolts for accumulator, valve housing socket bolts, valve cover socket
bolts and bracket bolts.
Also be sure to tighten again any loose bolts and nuts according to the specified torque.
Using the hydraulic breaker with loose bolts and nuts will cause not only oil leakages but also
damages to the screw threads and breakeage to the bolts. These can lead also defective operation.
(2) After first 10 hours of operating, retighten the bolts and nuts of all components and sections.
(3) At first, lightly tighten the bolts and nuts by referring to the following torque force.
The bolts and nuts should be screwed down alternately and diagonally until the bolts and nuts are
tightened to the uniform torque.
■ Through bolt
Model Torque(N·M) Model Torque(N·M)
40 400 135(F) 2700
45 500 140(A)/150 3000
53 700 155/165 3200
68 1200 165F 3300
75 1300 175/175F 3500
80 1500 185F 3600
85 1600 195 3700
100 2000 210 4000
125 2500
■ Bracket bolt

Model Torque(N·M) Model Torque(N·M)

40 320 135(F)/140(A)/150 3000
45 350 155 3500
53 400 165 3500
68/75/80 1200 165F 3500
85 1300 175/175F/185F 3700
100 2000 195 3800
125 2500 210 4000

■ Socket bolt-Valve cover

Model Torque(N·M)
135/135F 440
150 440
175F/185F 780
195/210 1400

-36-
 operation＆maintenance manual

■ Socket bolt—Valve housing

Model Torque(N·M)
135/135F 440
150 440
175F/185F/195/210 1565

■ Socket bolt-Accumulator cover

Model Torque(N·M)
135/135F 330
140/140A 330
150/165(F) 330
175 440
175F/185F/195 780
210 1100

■ Accumulator body
Model Torque(N·M)
135(F)/140(A) 780
155/165 440
150 1565
165(F)/175 440
175F/185F/195 1960
210 2500

■ Flange adaptor
Model Torque(N·M)
135/135F 150
150 150
175F/185F/195 440
210 780

-37-
operation＆maintenance manual

■ Bolt-Mount cap

TYPE BRACKET BOLT TORQUE（N.M）

40 BOX M14*2-60 165
45 BOX M14*2-65 165
53 BOX M14*2-65 165
TOP M20*2.5-85 500
68
BOX M20*2.5-85 500
TOP M20*2.5-85 500
75/80
BOX M20*2.5-85 500
TOP M20*2.5-85 500
85
BOX M20*2.5-85 500
TOP M20*2.5-85 500
100
BOX M20*2.5-85 500
TOP M24*3-110 880
125
BOX M24*3-110 880
TOP M24*3-120 880
135/135F
BOX M24*3-120 880
TOP M30*3.5-120 1750
140
BOX M24*3-120 880
TOP M30*3.5-120 1750
150
BOX M30*3.5-120 1750
TOP M30*3.5-120 1750
155
BOX M30*3.5-120 1750
TOP M30*3.5-130 1750
165/165F
BOX M30*3.5-130 1750
TOP M36*4.0-160 2200
175
BOX M36*4.0-160 2200
185F TOP M36*4.0-160 2200
195 TOP M36*4.0-160 2200
210 TOP M36*4.0-160 2200

-38-
operation＆maintenance manual

5-13. Storage

■ When operation is interrupted or finished

When operation is interrupted or finished, move the base machine on level ground. Remove mud
from the hydraulic breaker and set the hydraulic breaker on wood blocks.

CAUTION
● Do not touch the tool when hydraullic breaker just stop working, because
it’s very hot.

- Check whether oil leaks from hydraulic system and whether the tool oil is damaged.
- If the hydraulic breaker is operated in river, dry the hydraulic breaker body and apply the
grease to the front head.

■ When hydraulic breaker is not used for a long time-3 weeks or more

CAUTION
● If the following procedures are neglected, the rust is generated in the main
body to cause serious troubles.

- Discharge the nitrogen gas with the back head and accumulator, and then push the piston to
avoid rust the cylinder.
- Assemble the tool and store the hydraulic breaker indoors after applying the grease to every
part, especially internal parts of front head.

-39-
 operation＆maintenance manual

6. Operation

Before starting the base machine which the hydraulic breaker is mounted, check to use the machine
safely and to prevent any trouble.

6-1. Tool installation

■ Installation
CAUTION

● Personal injury can result from

dropping the tool during replacement.
● Be sure to use a crane when handing
the tool and such heavy parts.

WARNING
● Wear the safety shoes to protect feet.

1) Set the hydraulic breaker horizontally on wood blocks so that the accumulator may be upper side.
2) Remove the rubber plug or spring pin①and the stop pin ② into front head from opposite side by using
a hammer and a press pin. (Press pin is stored in tool box)

NOTICE
● Before tapping the stop pin, make sure that there is no person where they come out.
● After the rubber plug ① removed and installed 2 or 3-times, the rubber plug ① by
new ones.
3) Lift up the tool pins ③ after insert the press pin into the hole
of tool pin from bottom side, and remove the tool pins from
front head.
4) Insert the tool into front head.

NOTICE ③

● Apply the grease on the surface of shank

area and impact area of tool.
②
5) Insert tool pins, and then assemble the stop pin and ①
rubber plug or spring pin in front head.
6) Using a hammer and a press pin, fasten the rubber plug
or spring pin into front head.

■ Removal
The removal of tool in reverse order of installation.

-40-
operation＆maintenance manual

6-2. Safety operation

1) Precautions for safety operation

CAUTION
● Injury or death can result from improper operation or poor maintence.
● Make sure of the safety from any trouble or any accident around the
base machine before starting.

Inspection
Check the base machine and the hydraulic breaker to use safely and to prevent any trouble before operation.
Warming up the machine
Especially in winter or cold area, warm up the base machine at first before the breaker operation.
Safety maintenance
Before starting the work, examine the geological and geographical features of work site and be careful of
the ground crack or the building collapse.

2) Cautions, when driving or stopping base machine

Driving
Carry out driving while the hydraulic breaker is kept horizontally with ground and is 40 to 50cm above
ground.
Cautions on slope driving
When driving down on the slope, decrease the engine rpm and keep the angles with boom and arm 90°to
110°
Stopping
When the machine is stopped, the hydraulic breaker stand vertically and set the tool end on the groud.

-41-
 operation＆maintenance manual

3) Safety operation

Stop working the hydraulic breaker, if hydraulic hoses vibrate

excessively.
Check the N 2 gas pressure of accumulator & back head of
hydraulic breaker.

Stop the hydraulic breaker operation as soon as the object is broken.

If operation continued, idle blows, could result in excessive wear of
major components, or parts damage such as inner bush or piston.

Do not use hydraulic breaker to move rocks with end of tool or

hydraulic breaker body.

Do not use tool as a lever.

Hydraulic breaker could be damaged at through bolt, tool, front head,
inner bush and front cover.

Move impact point of object, if the object is not broken within 30

seconds.

Do not use hydraulic breaker in water. Corrosion of hydraulic breaker,

or non-lubrication, could result in further damage of the hydraulic
components.

-Under water kit must be installed when hydraulic breaker works in

water.
Please contact our dealer, if you need.

-42-
operation＆maintenance manual

Do not use hydraulic breaker as hammer.

Because hydraulic breaker is much heavier than excavator bucket,
such usage could result in damage of the front head or swing
mechanism of the base machine.

Do not operate hydraulic breaker with boom or arm cylinders fully

extended(bottomed out).
This may result in hydraulic breaker shock, and damage to the base
machine.
Maintain 100mm cylinder stroke of base machine at least.

Do not curl the tool tip into arm or boom of base machine when
travelling or parking carrier.

Do not strike in one spot for more than 30 seconds.

If object is not broken, stop breaking and change the spot of object.
Working too long in one spot will create excessive stone dust under
tool. Dust dampens impact effect, and can be damage piston seal.

Never use hydraulic breaker as a transporter.

This could result in tipping carrier, or damaging on base machine.

Operate the hydraulic breaker only to the front and rear of base
machine.
Do not use hydraulic breaker at either side of base machine.
This may result in tipping excavator, or damaging carrier swing
device.

-43-
 operation＆maintenance manual

6-3. Function of adjuster (135/135F/150/175)

6-3-1. Cylinder adjuster

The hydraulic breaker is designed so that the bpm (blows per minute) can be adjusted with the
operating pressure and oil consumption kept constant by changing the piston stroke, enabling the
hydraulic breaker to be used widely.
However when the bpm is increased, the impact force will decrease.
Therefore the bpm must be adjusted in accordance with job condition.

Adjuster

Nut Bracket

The cylinder adjuster is installed to the right side of the cylinder.

NOTICE
● The cylinder adjuster is fully tightened when the breaker is delivered.

When the cylinder adjuster is tightened fully, the piston stroke become maximum and the impact
blows(bpm) becomes the minimum.
The other way, when the adjuster is loosened about two turns, the piston stroke becomes the minimum
and the impact blows(bpm) becomes the maximum.

NOTICE

● Even the adjuster is loosened over two turns, the impact blows does not increase any more.

-44-
operation＆maintenance manual

6-3-2. Valve adjuster

The valve adjuster is installed on the valve housing.

The impact blows and the oil consumption increase when the adjuster is opened and when it is closed, the
impact blows and the oil comsumption decrease.
When the oil flow from base machine is lower or when the hydraulic breaker has been installed on large
base machine,the valve adjuster can control amount of oil flow artificially.

NOTICE
● The hydraulic breaker do not operate if the valve adjuster is fully closed.

Nut
Valve adjuster
Nut

Valve adjuater

■ Adjustment

Oil flow Operating Impact

Adjusting items Procedure rate pressure Bpm power At delivery

Open No change No change Increase Decrease Fully

Cylinder adjuster
Closed No change No change Decrease Increase closed

Open Increase Decrease Increase Decrease 21/2 Turn

Valve adjuster
Closed Decrease Increase Decrease Increase out

Charging pressure Increase Decrease Increase Decrease Increase

Specified
in back head Decrease Increase Decrease Increase Decrease

-45-
 operation＆maintenance manual

7. Trouble-Shooting

This trouble-shooting guide has been prepared to aid the operator to locate the problem cause and then
remedy when trouble has occurred. If trouble has been caused, obtain details as following check points
and contact your local service shop or distributor.

NOTICE

● Check below mentioned items and contact service shop to check and repair
any item which operator cannot remedy.

■ Check point

Check point(Cause) Remedy

1. Spool stroke is insufficient. After stop engine,
depress the pedal and check if spool moves full ◆Adjust pedal link and control cable joint.
stroke.

2. Hose vibration becomes bigger when hydraulic ◆Recharge with nitrogen gas or check.
breaker operation.
◆Recharge with gas.
◆High pressure line oil hose vibrate excessively.
If accumulator or back head is recharged
(Accumulator gas pressure is lowered)
◆Low pressure line oil hose vibrate excessively. but gas leaks at once, diaphragm or
(Back head gas pressure is lowered) charging valve may be damaged.

◆Pull out tool and check.

3. Piston operates but does not strike tool. (Tool
shank is damaged or seizing.) If the tool is seizing, repair with grinder or
change the tool and/or tool pins.
4. Hydraulic oil is insufficient. ◆Refill hydraulic oil.
5. Hydraulic oil is deteriorated or contaminated. ◆Change all hydraulic oil in hydraulic
◆Hydraulic oil color change to white or no system of base machine.
viscous.(White colored oil contain air bubbles or water.)

6. Line filter element is clogged. ◆Wash or replace the filter element.

7. Impact rate increases excessively. (Breakage or ◆Adjust or replace damaged part and
misadjustment of valve adjuster or nitrogen gas check nitrogen gas pressure in back head.
leakage from back head.)

8. Impact rate decreases excessively. (Back head ◆Adjust nitrogen gas pressure in back head.
gas pressure is excess.)

9. Base machine meander or weak at traveling. ◆Contact base machine service shop.
(Base machine pump is defective or improper set of
main relief pressure.)

-46-
operation＆maintenance manual

■ Trouble shooting guide

Symptom Cause Required action

1. Excessive nitrogen gas pressure 1. Re-adjust nitrogen gas
of back head pressure in back head
2. Stop valve(s) closed 2. Open stop valve
3. Lack of hydraulic oil 3. Fill hydraulic oil
No blow 4. Wrong pressure adjustment from 4. Re-adjust setting pressure
relief valve 5. Tighten or replace
5. Faulty hydraulic hose connection 6. Replace back head o-ring, or
6. Hydraulic oil in back head seal retainer seals
infection

1. Line leakage or blockage 1. Check lines

2. Clogged tank return line filter 2. Wash filter, or replace
3. Lack of hydraulic oil 3. Fill hydraulic oil
4. Hydraulic oil contamination,or 4. Replace hydraulic oil
heat deterioration 5. Contact authorized service shop
Low impact power 5. Poor main pump performance 6. Refill nitrogen gas
6. Nitrogen gas in back head lower 7. Re-adjust valve adjuster
7. Low flow rate by mis-adjustment 8. Push down tool by excavator
of valve adjuster operation
8. Tool out of range for blowing
position

1. Low nitrogen gas pressure in 1. Refill nitrogen gas and check

accumulator accumulator. Replace diaphragm if
Irregular impact 2. Bad piston or valve sliding surface need
2. Contact authorized local
3. Piston moves down/up to blank distributor
blow hammer chamber. 3. Push down tool by excavator
operation

1. Tool diameter incorrect 1. Replace tool with genuine parts

2. Tool and tool pins would be 2. Smoothen rough surface of tool
jammed by tool pins wear 3. Smoothen rough surface of
Bad tool movement 3. Jammed inner bush and tool inner bush. Replace inner bush if
4. Deformed tool and piston impact need
area 4. Replace tool by new

Sudden reduction power 1. Gas leakage from accumulator 1. Replace diaphragm if need
and pressure line vibration 2. Diaphragm damage

Oil leakage from front cover 1. Cylinder seal worn 1. Replace seals

Gas leakage from

1. O-ring and/or gas seal damage 1. Replace related seals
back head

-47-
 SIDE/TOP TYPE TOOL PARTS LIST
operation＆maintenance manual

DOUBLE END SINGLE END L-WRENCH RING OTHER EYE BOLT HOSE
WRENCH WRENCH WRENCH EXTENDED SPRING PIN TOOLS
TOOLS REMARKS
BREAKER TYPE PIN BAR BAR PLUG(2)
FOR ALL
40(SIDE/TOP) 27*30 19*22 24 5 1/2"
45(SIDE/TOP) 27*30 19*22 5 1/2"
53(SIDE/TOP) 27*30 19*22 36 5 1/2"
68(SIDE/TOP)
27*30 19*22 5 10（12 17） 41 1/2"
（ACC）
75/80(SIDE/TO
27*30 19*22 5 10（12 17） 41 46 1/2"
P)（ACC）
85(SIDE/TOP)
30*32 19*22 27 36 5 8 10（17） 50 46 3/4"
（ACC）
100(SIDE/TOP)
30*32 19*22 27 36 5 8 12（17） 55 3/4"
（ACC）
125(SIDE/TOP) 19*22 30*32 36*41 27 5 8 12 65 1"
SOCKET
135(SIDE/TOP) 30*32 36*41 19*22 27 5 8 12 14 17 19 65 75 1"
SPANNER
WHICH
135F(SIDE/TOP) 30*32 36*41 19*22 27 5 8 12 14 17 19 65 75 14# PIN 1"
IS

-48-
BAR
140(TOP) 36*41 19*22 27 46 50 5 8 12 14 75 APPLIE 1"
N2 GAS
D TO
E140(SIDE) 19*22 27 41 50 5 8 12 14 75 HOSE 1"
SPRING
ASSY.
140A(TOP) 36*41 19*22 27 46 50 5 8 12 14 19 75 PIN 1"
N2 GAUGE
FOR
140A(SIDE) 19*22 27 41 50 5 8 12 14 19 75 ASSY. 1"
STOP
150(TOP) 30*32 36*41 19*22 27 34 46 5 8 12 14 17 22 75 70 PIN 1"
150(SIDE) 30*32 36*41 19*22 27 34 5 8 12 14 17 22 75 70 1"
155(TOP) 30*32 19*22 27 34 46 55 41/50 5 8 12 14 17 19 22 75 85 1"\11/4"
8-1. Standard service tools

∅18
155(SIDE) 30*32 19*22 27 34 55 41/50 5 8 12 14 17 19 22 75 85 ∅18 1"\11/4"
165(TOP) 30*32 19*22 27 34 46 50 55 5 8 12 14 17 22 75 85 M12 ∅18 11/4"
8. Service tools

165(SIDE) 30*32 19*22 27 34 50 55 5 8 12 14 17 22 75 85 M12 ∅18 11/4"

165F(SIDE) 36*41 30*32 19*22 27 50 55 5 6 8 12 14 17 19 22 85 M12 ∅18 11/4"
165F(TOP) 36*41 30*32 19*22 27 46 50 55 5 6 8 10 12 14 17 19 22 85 M12 ∅18 11/4"
175(SIDE/TOP) 36*41 30*32 19*22 50 55 5 12 14 17 22 85 M12 ∅26 11/4"
175F(SIDE/TOP) 19*22 41 46 27 50 55 5 6 8 10 12 14 17 19 22 27 85 ∅15X190 M10 11/4" M12*80(SOCKETBOLT)2
185F(SIDE/TOP) 19*22 41 46 27 50 55 5 6 8 10 12 17 19 22 27 85 90 ∅15X190 M10 ∅26 11/4" M12*80(SOCKET BOLT)2
195(SIDE/TOP) 19*22 41 46 27 50 55 5 6 8 10 12 17 19 22 27 95 ∅15X190 M10 ∅26 11/4" M12*80(SOCKET BOLT)2
210(SIDE/TOP) 19*22 36*41 27 50 55 6 10 12 14 19 22 36 105 ∅15X250 M10 M16(2) ∅26 11/4" M12*80(SOCKET BOLT)2
 BOX TYPE TOOL PARTS LIST

BREAKER DOUBLE END WRENCH SINGLE END WRENCH L-WRENCH RING OTHER EYE SPRING PIN HOSE TOOLS RUBBER
TYPE WRENCH TOOLS BOLT BAR PLUG(2) PLUG(2)
FOR ALL

40 27*30 19*22 5 1/2"

45 27*30 19*22 5 1/2"

operation＆maintenance manual

53 27*30 19*22 36 24 5 1/2"

68 27*30 19*22 5 10 （12 17） 41
（ACC） 1/2"
75/80 27*30 19*22 5 10 （12 17） 46 1/2"
（ACC）
85 30*32 19*22 27 36 55 5 8 10 12（17） 50 3/4" M20
（ACC） SOCKET
100 SPANNER
（ACC） 30*32 19*22 27 36 5 8 12（17） 55 3/4" M20

-49 -
14# PIN
125 19*22 30*32 36*41 27 55 5 8 12 65 BAR 1" M20
N2 GAS
135 30*32 36*41 19*22 27 5 8 12 14 17 19 65 75 HOSE 1" M24
ASSY.
135F 30*32 36*41 19*22 27 5 8 12 14 17 19 65 75 1" M24
N2
140 36*41 19*22 27 50 55 5 8 12 14 75 GAUGE 1" M24
ASSY.
140A 36*41 19*22 27 50 55 5 8 12 14 19 75 1" M24

150 30*32 36*41 19*22 27 34 46 5 8 12 14 17 22 75 70 1" M24

155 30*32 19*22 27 34 46 55 41/50 5 8 12 14 17 19 22 75 M12 18 1"\1 41" M24

165 30*32 19*22 27 34 46 50 55 5 8 12 14 17 22 75 M12 18 141" M24

165F 36*41 30*32 19*22 27 46 50 55 5 6 8 12 14 17 19 22 85 M12 18 141" M30

175 36*41 30*32 19*22 27 50 55 5 12 17 22 85 M12 26 141" M30

operation＆maintenance manual

8-2. Nitrogen gas charging kit

1
4
2

◎Charging kit detail

No. Part Name Q＇

ty

1 Pressure gauge 1

2 Charging gauge 1

3 Cap 1

4 Gas hose 1

5 N2 gas cylinder 1

-50-
 operation＆maintenance manual

9. Tool selection
9-1. Guide to tool choice

● Tool Type
№ Type Sketch map Name
Moil(universal)
1 M
standard type we supply
Moil
2 Conical point C

3 H-Wedge H
Chisel
(flat)
4 V-Wedge V

5 Blunt Blunt B

Note The drawings above are just for identifying different types of tool Tip

● Application Instruction ● Tool Dimension

Dia. Length Weight Note
No Model
mm mm Kg

1 40 40 450 4

2 45 45 500 8

3 53 53 580 9
Moil Point
4 68 68 702 18
This tool is suitable for common breaking work
during which accurate control of the cut is not 5 75 75 710 22
required.
6 80 80 745 26

7 85 85 1055 29

8 100 100 1130 57

9 125 125 1200 94

10 135(F) 135 1200 115

Chisel Point 11 140(A) 140 1300 126

Most ordinarily used tool for demolition work. 12 150 150 1300 157
Available in both in-line and cross cut.
13 155 155 1500 190

14 165 165 1500 224

15 165F 165 1500 215

16 175(F) 175 1600 260

Blunt Point
This tool is appropriate for breaking oversize 17 185F 185 1700 283
material and concrete pads where a chisel point
18 195 195 1800 353
may go through too quickly.
19 210 210 1800 416

-51-
operation＆maintenance manual

9-2. Tool claim judgment

Hence, to help users to use our products correctly, and ensure long operating life, these claim judgement
criteria present defect examples that can occur during use, and the disposition standards applicable in
each case.

■ Breakage of piston impact area or tool pins contact corners(Fig.1 and 2)

Breakage of piston impacting point or of tool pins contact corners is extremely rare. This phenomenon
occurs or when striking force is being concentrated on the tool corners due to unsatisfactory flatness of
piston and tool impacting point. If such defect occurs, affected tools may not be accepted under warranty.

(Fig.1)

(Fig.2)

-52-
 operation＆maintenance manual

■ Plastic deformation of piston impact area (Fig.3)

The possibility of tool tip plastic deformation occurring due to piston is extremely slim. Such defects may
occur due to material strength deficiency, or brittleness, resulting from unsatisfactory heat-treatment. If
such defect occurs, affected products may be accepted under warranty.

(Fig.3)

■ Breaking inside basic line (Fig.4 and 5)

Should product breakage occur in any direction occur in any direction at a point inside the front cover, as
shown in <Fig.5>, from the basic line shown in <Fig.4>, this may be due to defective material, defective
heat-treatment; tool deformation, or unsatisfactory shapoing of tool neck. Should such defect occur,
affected products may be adopted under warranty.

In addition to the causes described above, product breakage inside the basic line may also occur if the
interval between the front cover and tool widens due to excessive wear of front cover, coupled with
excessive bending load being applied to hydraulic breaker, if any trace of seizure, caused by friction
between the front cover and tool, is observed on the surface of the tool body, and if it is clear that product
breakage is centered around the area of such seizure, affected products may be rejected under warranty.

-53-
operation＆maintenance manual

Basic Line
lnside Outside

front cover

lnner bush
(Fig.4)

(Fig.5)

■ Breakage outside basic line (Fig.6, 7 and 8)

Should product breakage occur at a point outside the front cover, as shown in <Fig.6>, from the basic line
shown in <Fig.4>, this may be due to excessive bending load being applied to the tool. Such bending load
occurs when, after tool has been inserted into material, the tool is pulled or pushed, or when the tool is
struck and pushed when it is not perfectly perpendicular to the surface of the material being worked on.
Fractures, in general, are of the form shown in <Fig.7>. Fatigue breakage, of clamshell form, develops in
the areas near breakage start points, caused by stress concentration resulting from bending loads, and
then quickly radiates outward, such type of breakage may also occur due to scarring of the tool body
during use, as breakage occuring outside the basic line are caused by improper working habits, as
explained above, products incurring such defects shall not be accepted under warranty. However, if a
fatigue fracture start point occurs within the tool body, instead of on the surface of tool as shown in
<Fig.8>, affected products will be accepted under warranty, as such breakage indicates material defect.

-54-
 operation＆maintenance manual

(Fig.6)

(Fig.7)

(Fig.8)

-55-
operation＆maintenance manual

■ Crushing of tool tip (Fig.9)

Breaker tools are heat-treated to exhibit high breakage-and wear-resistance; and defects such as
crushing of the tool tip <Fig.9> are not to be expected under normal operating conditions. However, if a
tool is hammering continuously for a long period of time without crushing or puncturing the material being
worked on, the temperature of the tip rises extremely high, inducing annealing of the heat-treated
material, and bringing on plastic deformation (crushing), rather than wear, as explained above, crushing of
the tool tip is caused by improper working methods, and, therefore, affected products will be rejected
under warranty.

(Fig.9)

■ Tool tip wear (Fig.10)

The rates and types of tool tip wear vary with work material and work method. If the diameter of the worn
tip of a chisel point tool is less than 2/3 of the tool body diameter, as shown in <Fig.10>; and if the tip of a
new pointed tool is worn down in excess of 5mm lengthwise from the tip, this is considered normal tool
wear, Hence, tools exhibiting such normal wear, as shown in <Fig.10>, will be rejected warranty claim.

D 2
3D

(Chiel point tool) (Pointed tool)

(Fig.10)

-56-