Breaker Operator's and Services Manual

OPERATOR & SERVICE MANUAL
FOR THE HYDRAULIC BREAKER
Operator's & Service Manual.indd 1
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Operators Manual Foreword
OPERATORS MANUAL FOREWORD

Breaker Operators Manual
This Breaker Operators Manual is intended to serve

as a supplement to the Operators Manual of the
machine and should be read together with it. Keep this
manual in the cab, so that it is always at hand. Replace
it immediately if lost.
Table of Contents
The Breaker Operators Manual is written to apply to

several markets. Therefore, we ask you to disregard
the sections in the manual that describe equipment
which is not valid for your market.
Presentation
Many hours are spent on design and production to

make equipment that is as efficient and safe as
possible. The accidents which occur in spite of this,
are mostly caused by human error. A safety conscious
operator and well maintained equipment make a safe,
efficient and profitable combination. Therefore, read
the safety regulations and follow them.
Safety
Operating Instructions
Service and Maintenance
We continually strive to improve our products and

make them more efficient through changes to their
design. We retain the right to make these changes
without committing ourselves to introducing these
improvements on products which have already been
delivered. We also retain the right to change data and
equipment, as well as instructions for service and
maintenance without prior notice.
Specifications
Be sure you are thoroughly familiar with the positions

and functions of all instruments and controls of the
machine, along with the Operators Manual before using
the equipment or before service and maintenance is
carried out.
WARNING!
The symbol above appears at various points in the

manual together with a warning text. It means:
Warning, be alert! Your safety is involved! It is the
operators responsibility to ensure all warning
decals are in place on the machine and are
readable. Accidents may otherwise occur.
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Operators Manual Foreword
WARNING!
Do not operate this breaker and do not carry out any

maintenance until you have thoroughly studied and
understood the contents of this manual.
Installation Inspection
An inspection must be carried out after the breaker
has been installed. During the inspection certain
specifications (working pressure, oil flow, etc.) are to be
checked to ensure they fall within given limits. Contact
Product Support.
Spare Parts Order

When you need parts or some information concerning
maintenance of your equipment, contact Customer
Support.
Required Information:
1. Name of customer and contact person
2. Order number (when available)
3. Delivery address
4. Mode of delivery (air mail, etc.)
5. Required delivery date
6. Invoicing address
7. Model and serial number of product
8. Name, number and required amount of spare parts
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Operators Manual Table of Contents
OPERATORS MANUAL TABLE OF CONTENTS

OPERATORS MANUAL FOREWORD
CONTENTS
PRESENTATION
Removal from Packaging

Lifting Instructions
Lifting Eyes
Main Structure of the Hydraulic Breaker
Plates & Decals
Choosing Tools
Adjuster Valve to Control Impact Blows
Special Conditions of Use
Correct Working Practice
Precaution for Operation
Working in High-Temperature Conditions
Working in Low-Temperature Conditions
Key Points in Tool Usage
Removal & Installation of the Breaker
Remove the Breaker
Storage Maintenance
Travelling Position
Washing the Attachment

Oil & Lubrication
Correct Greasing
Tool
13
Principles of Breaking
Service Intervals in Special Applications
OPERATING INSTRUCTIONS
Operating Temperature
Recommended Wear Parts Replacement Schedule
10
Operating Conditions
Service Intervals
SAFETY
Recommended Use
SERVICE AND MAINTENANCE
Replacement of the Tool

Tool Pin
Tool Pin Wear Limits
13
Cause of Tool Damage
14
SPECIFICATIONS
14
25
25
26
27
27
27
27
29
29
30
31
34
35
14
14
14
15
17
18
21
21
22
22
22
23
24
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Presentation
PRESENTATION
The breaker is hydraulically powered. It can be

used on any machine of the proper weight, with an
adequate hydraulic system and which meets necessary
mechanical installation requirements. The unit functions
by repeatedly raising a steel piston and driving it down
onto the head of a removable breaking tool.
The wooden frames and boxes can be recycled.

Check the breaker is in good condition and there is
no visible damage.
Check that all ordered parts and accessories have
been enclosed with the product.
No additional pressure accumulators are necessary

since the integrated pressure accumulator (where
required) absorbs hydraulic pressure peaks. The
impact energy of the breaker is almost constant and
independent of the machines hydraulic system.
Removal from Packaging

Remove all the steel belts from the packaging.
Open the packaging and remove all plastics
covering the product. Scrap the steel belts and
plastics.
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Presentation
Lifting Instructions
Lifting Eyes
WARNING!
WARNING!
Ensure lifting eyes are fully tightened to the housing

before use. If a lifting eye is not properly tightened
it may break. If the breaker falls there is a risk of
personal injury.
Ensure there are no personnel near the breaker

when it is lifted. If the breaker falls there is a risk of
personal injury.
Use a hoist when lifting the breaker or component parts
to avoid back injury. Make sure all chains, hooks, slings,
etc. are in good condition and of the correct capacity.
Be sure the hooks are positioned correctly.
Lifting eyes on the breaker housing are intended only

for handling the breaker. It is not permissible to use the
breaker or its parts for lifting other products.
Lifting devices must safely carry the working weight of

the breaker, see the specification chapter. Position the
chains or slings as shown in the illustration.
IMPORTANT! Always remove lifting eyes and replace

them with blanking screws before operating the
breaker.
Always check the balance of the breaker by lifting it a

few centimeters. If the breaker is well balanced it may
be lifted higher.
IMPORTANT! Always ensure lifting eyes are in good

condition. Damaged lifting eyes must not be used.
Follow the safety instructions for lifting equipment, see
Safety section.
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Presentation

The breaker consists of five main sections: Cylinder, Piston, Control Valve, Front Head and Back Head.
1. The cylinder contains the piston and valve.
2. Four through bolts are assembled and hold the cylinder and back head together with front head.
3. Piston strikes the tool by oil and gas pressure.
4. Control valve inside cylinder regulates piston movement.
5. Tool pins inside the front head retain the tool.
6. Back head contains charged Nitrogen gas.
0060, 0200
0260 - 7000
Through Bolt
Back Head
Control Valve
Cylinder
Piston
Accumulator
Front Head
Tool Pin
Tool
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Presentation
Plates & Decals

Reference
Image Content
Hearing protection
must be worn
Head wearing
ear protection
Consult manual for proper

service procedures
Vacate work area while the breaker

is in operation
Signs
Technical
Manual
A working breaker with

diagonal slash
Inject grease into the hole

with grease gun periodically
Grease
Gun
HIGH PRESSURE requires

dis-charging before disassembly
Accumulator,
Back Head
Caution - the breaker is HOT
High Temperature
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Safety
SAFETY
Care and Alertness
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.
Always take care and stay alert when working with

the breaker. Always be careful. Always be alert
for hazards. The possibility of a serious or even fatal
accident is increased when you are under the
influence of alcohol or drugs.
Accidents can often be avoided by recognising

potentially hazardous situations before the incident
occurs.
Clothing
Suitable safety clothing should be worn.
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.
Use a hard hat, safety glasses, protective shoes and

gloves and an approved respirator (dust mask) or
other protective articles when required.
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.
Keep other persons away. Do not perform new

operations until you are sure you can do them safely.
Training
You and others can be killed or injured if you perform
unfamiliar operations without practicing them first.
Practice away from the job site, in a clear area.
Communication
Bad communication can cause accidents. Keep people
around you informed of what you will be doing. If
working with other personnel, make sure they
understand any verbal or non-verbal signals you will
be using.

Work sites can be noisy. Do not rely only on spoken
commands. See the signaling diagram in the
Operators Manual of the machine.
WARNING!
Read the following warning messages carefully. They

inform you of hazards and how to avoid them.
If proper precautions are not taken you or others
could be seriously injured.
Operators Manual
Work Site
Read and understand the Operators Manual.
Work sites can be hazardous. Inspect the site before

working on it.
The machine operator must be thoroughly familiar

with how to operate and maintain the breaker and
should preferably undergo training on the breaker.
Check for potholes, weak ground, hidden rocks, etc.

Check for utilities (electric cables, gas and water
pipes, etc.). Mark the positions of underground cables
and pipes if you will be breaking the ground.
The machine operator must follow the rules and

recommendations in this manual and the Operators
Manual for the machine, but also pay attention
to any statutory and national regulations or specific
requirements or risks that apply to the work site.
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Safety
Banks and Trenches

Banked material and trenches can collapse. Do not
work too close to banks and trenches where there is a
danger of collapse.
Safety Barriers
Unguarded equipment in public places can be
dangerous. Place barriers around the machine to
signify a safe working area.
Flying Chips of Rock

Protect yourself and the work area against flying chips
of rock. Do not operate the breaker or the machine if
someone is too close.

Keep windows and doors closed during operation.
Only machines with enclosed cabs may be used for
breaker operation. For skid steers, a special
application (demolition door) must be fitted when
operating.
Never use your hand when looking for leaks since oil
under high pressure may penetrate your skin.
Pressure Accumulators
The breaker may incorporate one or two pressure
accumulators. The accumulators are pressurised even
when there is no hydraulic pressure to the breaker.
Attempting to remove or dismantle the accumulators
without first releasing the pressure can cause injury
or death. Do not try to dismantle pressure
accumulators, contact an authorised dealer.
Equipment Limits
Operating the breaker beyond its design limits can
cause damage and can also be dangerous - see
Specification section.
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that the lifting equipment is in good
condition. Make sure that the lifting tackle complies
with all local regulations and is suitable for the job.
Make sure the lifting equipment is strong enough for
the job and you know how to use it.

Do not use the breaker, or any of its parts, for lifting.
Contact an authorised dealer to find out how to lift
with your machine.

Never leave a lifted breaker, or any other lifted load,
unattended.
Do not try to enhance the performance of the breaker

by unapproved modifications.
Hydraulic Pressure
Hydraulic oil at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses,
turn off the engine, operate the controls to release
pressure trapped in the hoses and wait 10 minutes.
During the operation, keep persons away from the
hydraulic hoses.

Fine jets of hydraulic oil at high pressure can
penetrate the skin. Do not use your fingers to check
for hydraulic leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
the suspected leak then inspect it for signs of
hydraulic oil. If hydraulic oil has penetrated your skin,
seek medical treatment immediately.

There might be pressurized oil trapped inside a
breaker even if it is disconnected from the machine.
Be aware of possible blank firing while greasing or
removing and installing breaker tools.
Follow the Lifting Instructions, see page 7.
Spare Parts
Use only genuine spare parts. Use only genuine tools
with hydraulic breakers.

The use of non-genuine or counterfeit parts may
damage the breaker.
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Safety
Equipment Condition
Defective equipment can injure you and others. Do not
operate equipment which is defective or has missing
parts.

Make sure the maintenance procedures in this manual
are completed before using the product.
Repairs and Maintenance

Do not try to do repairs or any other maintenance
work you do not understand.
Modifications and Welding

Non-approved modifications can cause injury and
damage. Contact your local dealer for advice before
modifying the breaker. Do not attempt to weld the
breaker. If in doubt, contact a dealer. Note that
welding breaker tools will render them useless.
Metal Splinters
You can be injured by flying splinters when driving
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.
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OPERATING INSTRUCTIONS
Recommended Use
The breaker is designed for breaking concrete, road
surface / asphalt, hard or frozen ground. It is also
suitable for light trenching and benching applications or
for ground compacting. It can also be used for breaking
small and soft boulders.
Breaker Selection
Description
0060
0120
0200
0260
0350
0500
0550
0800
0900
1200
1550
1600
1800
2000
2500
3000
3500
4000
7000
Primary Breaking
Secondary Breaking
Hard Rock Removal
Soft Material & Rock Removal
Demolition
Description
Primary Breaking
Secondary Breaking
Hard Rock Removal
Demolition
Description
Primary Breaking
Secondary Breaking
Hard Rock Removal
Demolition
Note: Please consult with the dealer when selecting breaker model for your applications.
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Operating Conditions
Impact Breaking
With impact breaking, the material is broken by
transferring very strong mechanical stress waves from
the tool into the material. The best possible energy
transfer between the tool and the object is achieved
with a blunt tool. Impact breaking is most effective in
hard, brittle and very abrasive materials. The use of a
point tool in hard material will cause the sharp edge to
wear very quickly.
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
equipped with such a circuit, only suitable hoses and
fittings are required. If the machine does not have
a suitable circuit for running the attachment, one
must be ordered from your dealer. This may require
more complex installation, including new piping and
additional valves such as a directional valve and
pressure relief valve.
Operating Temperature
The operating temperature is -20C to +80C (-4F to
+176F) for 0060 - 7000. If the temperature is below
this range, breaker and tool require preheating before
operation. Operating at too low a temperature can
damage the accumulators membrane and tool. During
operation they will remain warm.
Choosing Tools
A selection of standard and special tools are available
to suit every application. The correct type of tool is
required for optimum possible results and maximum
tool life. Choosing the best tool type for an application
may require some experimentation. Tool availability
depends on breaker model - contact an authorised
dealer for more information.
NOTE! The temperature of the hydraulic oil must be

monitored. Correct oil grade and temperature will
ensure correct oil viscosity.
Principles of Breaking
To increase the working life of the breaker correct
working method must be adhered to, and the correct
tool chosen for the job. There are essentially two ways
of breaking with a hydraulic breaker.

See Tool Selection page 29.
Penetrative Breaking (or Cutting)
The blow rate of the breaker is affected by oil flow and

pressure from the carrier (0060 - 7000).
In this form of breaking, a moil point or chisel tool is

forced into the material. This method is most effective
in soft, layered or plastic, low abrasive materials.
Stroke adjustment to suit working conditions:

For secondary breaking and lime stone / soft
rock, high speed (low power) is more productive.
For primary breaking and hard rock, high power
(low speed) blows are more productive.
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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.
The blow rate of breaker can be adjusted with following

procedure;
1. Release the nut of adjuster.
2. High speed (Low power): turn adjuster to counterclockwise. (turn 2 cycle)
Low speed (High power): turn adjuster to clockwise.
(fully tighten)
Underwater Operation
The latest breaker models can be modified for
underwater operation for only short periods. The
operating principle in underwater breaking is to conduct
pressurised air through a built-in channel to the
space below the piston. The air pressure prevents
water entering the breaker. 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.
3. Tighten the nut of adjuster after setting.
The wear resistance of breaker parts is considerably

reduced under water due to corrosion and the abrasive
effect of mud in water. After use underwater, the
breaker must be inspected regularly - for example every
half hour of operation. Adapt the inspection intervals to
the working conditions.
Speed
Up
In underwater applications, productivity of a hydraulic

breaker is considerably lower than in normal work. This
is caused by:
Speed
Down
5mm L-wrenches
1. The breaking object is not visible to the operator,

causing misalignment between tool & object, and
unnecessary idle strokes.
2. The breaker must be inspected and greased more
often than in normal situations.
Special Conditions of Use

If the breaker is to be used in special conditions such
as;
3. The breaker must always be completely serviced

after working on underwater job sites.
tunnel application,
foundry cleaning,
underwater operations,
operations in extremely low or high temperatures,
use of special hydraulic oils,
other special conditions,
For further information on underwater operation,

contact an authorised dealer.
or for demolition work

..etc, it may require modifications, special operating
techniques, increased maintenance or special wear
items. Contact an authorised dealer for instructions.
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1. Safety First
If the breaker is connected to an attachment bracket,

special care must be taken to ensure the attachment
bracket does not sustain any damage.
When parking the carrier, lower the breaker to the

ground and turn the engine off.
Never attach a cable or sling to the breaker to hoist a
load. Doing so is extremely dangerous.

Remove the tool before transporting the breaker.

Keep all people and equipment away from the breaker
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
wear quickly.
4. Fitting / Removing the Tool
2. Prior Inspection
If the noise level exceeds 90 dB(A), all workers in the

immediate area, including the driver of the carrier,
must wear hearing protection.
Always wear protective glasses and helmet when

fitting or removing the tool.

Metal splinters may chip off when removing tool pins.

Never use your fingers to check alignment of the
recesses on tool to the slots for the retaining bars.

The tool shank must be well lubricated during
operation. Regular visual inspections during operation
are recommended. The greasing intervals are different
for the breaker models and vary with the working
conditions. See service and maintenance section.
Equipment Limits
Keep personnel away from the risk zone when the
breaker is in operation. It is the operators
responsibility to determine the risk zone.
Check there is sufficient hydraulic oil and that it is not

contaminated.

Check that hoses, bolts and nuts are secure.

Grease the shank part of the tool - see pages 27 - 28.
Stop the breaking immediately if any one moves

into the danger area, which is much larger for breaker
operation than for excavator operation due to the risk
of flying rock splinters.
3. Attaching the Breaker
Check the oil temperature constantly. Temperature

of the hydraulic oil must never exceed 80C. If higher
temperatures are measured in the tank, an oil cooler
must be fitted.
When attaching the breaker, an assistant is required

who must be instructed by an excavator driver. All
directions, signals etc. must agreed on beforehand.

The breaker should only be attached to an excavator
with sufficient load capacity. If the excavator is too
light it may become unstable under load and fall over.

Do not touch any parts when the boom is moving.

Check the pressure relief valve on the hydraulic
system.

Do not run any hydraulic lines through the drivers
cab. These lines may start to leak or even burst.
During operation, the hydraulic oil becomes very hot.
Never touch the breaker.
At temperatures lower than minus 20C, the breaker

should not be operated with cold hydraulic oil, the
seals in the breaker may be damaged. Warm the
engine up and move the boom around to raise oil
temperature before operating the breaker.
Only approved hydraulic oils should be used.
Do not operate the breaker with the hydraulic
cylinders fully extended or fully retracted. Damage to
the machine may result.
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When operating the breaker, make sure it does not

contact the machine or hydraulic lines.
Wear ear protection to prevent hearing impairment.

Anyone in the immediate vicinity of breaker
operations should also wear ear protection.

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.
Apply the correct feed force on the breaker: Too

much: Stabilizer leg feet are lifted from the ground or
tracks are completely lifted from the ground. Too little:
Tool does not stay firmly against material to be broken
and machine may start to shake.
Keep the tool perpendicular to the object at all times.
If the object moves or its surface breaks, correct the
angle immediately.
Correct Working Practice

1. Proper Thrust
Do not let the tool strike without resistance. Keep the

feed force on the breaker steady and aligned with the
tool during breaking.
To break effectively, a proper thrust force must be

applied to the breaker. If thrust is too low, impact
energy of the piston may not be sufficient to break
rocks. Breaking force is transferred to the breaker body,
arm and boom of the carrier resulting in damage of
those parts.
It is not usually effective to strike in one spot for more

than 15 seconds at a time. If the object does not
break, or if the tool does not penetrate, stop the
breaker and change position of the tool. Working too
long in one spot creates stone dust under the tool
which dampens the impact effect and produces heat.
Stop the breaker quickly. Do not allow the breaker to
fire with no pressure on the tool (dry fire / blank fire).
Frequent idle strokes will damage the breaker.
To use the breaker most efficiently concentrate on
the outer edge of the working area moving towards
the middle in small steps
When breaking hard or frozen ground, use the
benching method. Start by clearing a small area from
the edge. Then continue by breaking material towards
the open area.
When breaking concrete, hard or frozen ground, never
pry with the tool. The tool may break.
Operating
The following precautionary measures should always be
taken to rule out the risk of accident.
Only operate the hydraulic breaker from the drivers
seat in the excavator cab.
Close the front screen / splinter guard on the drivers
cab to avoid injury from flying rock splinters.

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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.
Precaution for Operation

The operator should observe the following instructions;
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.
Excessive force as above may also result in vibrations

being transmitted to the tracks causing damage.
Care is required to ensure adequate but not excessive
force is applied to the breaker in operation.
Stop as soon as breaking is completed. As soon
2. Direction of Thrust
as rocks are broken, cease power to the breaker. If idle

striking continues the accumulator may be damaged,
the bolts loosened or broken and also damage may be
caused to the excavator. When a proper thrust is not
applied to the breaker or the tool is used as a lever, the
state of idle striking will occur. (Idle striking makes a
higher pitched ringing sound.)
Thrust should be in line with the tool, which should be

positioned so the breaking direction is as near vertical
as possible. If the direction is oblique, the tool may
slip causing tool and piston to be broken or seized.
When breaking, ensure machine is in a suitably stable
position.
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Never use to move rocks. As shown in the picture, do

not roll or throw down a rock with the end of the tool
or the side of the bracket using the oil pressure for
the carriers boom, arm, bucket, swing or travelling
because the bolts of breaker may be broken, the
bracket damaged, the tool broken or scuffed, and the
boom or arm damaged. Never travel the machine with
the tool in a rock.
Never strike the same spot for more than 30 seconds.

If rocks are especially hard avoid continually striking
the same spot for more than 30 seconds. It is better
practice to change target periodically which avoids
raising the oil temperature. This can result in damage to
the accumulator and excessive tool wear.
On a hard, large rock, start breaking at the end point.

(advance). Begin with a target near the end of a large
rock, and advance in small steps. This will enable large
rocks to be broken easily. Advancing in large steps will
not generally improve efficiency.
Operate the breaker at a proper engine speed. The
breaker works at a typical engine speed for the carrier.
Increasing to the highest rpm level does not increase
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 lever with the breaker. Never attempt to use

the hydraulic breaker as a crowbar. The breaker is not
designed for lateral loads. Both breaker and tool will be
damaged.
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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
lower percussion piston zone would rust. Water could
also penetrate the carriers hydraulic system. In order to
avoid damage to the hydraulic breaker, a special kit has
been developed for under water operation.
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 as a sledge hammer. Before

starting up, rest the breaker on the ground. Never
attempt to use the breaker and excavator boom as a
sledge hammer to break material. This will damage
parts of the carrier.
Never use the breaker for lifting. Any use of the

breaker for lifting is not permissible and can be very
dangerous
Never strike with the cylinders of carrier extended

to the end of stroke. Excavator cylinder damage may
be caused if the breaker is operated with the arm
fully extended.
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To Prevent Blank Firing:

NEVER operate a breaker unless the tool is pressed
against a solid surface.
The auto-stop mode was introduced to stop operation

after one extra strike only once the piston extends
beyond its working range. High pressure is routed
directly to the return line and operation stops
immediately.
ALWAYS stop the breaker as soon as the tool breaks

through the material.
Efficiency of the auto-stop function has been proven

through actual operation at job sites.
NEVER operate the breaker without a tool.
Special care must be taken in certain operations

including secondary breaking of smaller objects where
breaking can be completed in 1-2 strikes. Continued
striking becomes a blank firing condition.
In this case to prevent unnecessary breaker and tool
damage;
Use Blunt type breaker tool.
Release the breaker pedal immediately after the
object is broken.
Working in High-Temperature Conditions

The temperature of the hydraulic oil must be
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
viscosity. In summer and tropical climates, the
minimum requirement is a hydraulic oil type ISO VG 68
HV. (Refer to page 27).
Working in Low-Temperature Conditions
The Effects of Blank Firing
For temperatures down to minus 20C there are no

special regulations, other than warming up the hydraulic
oil before operating. This is achieved by:
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.
Starting up the excavator motor.

Moving the boom.
This raises the oil temperature. Once it has risen above
0C, the hydraulic breaker can be started up. Leave the
motor and the pumps of the excavator running during
breaker in work.
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.
21
08/10/2014 15:51:21
Please Note:
Do not touch any parts for a while when the hydraulic

oil keeps on being hot. It may cause your hands to be
burned.

Never use your fingers to check the alignment of the
bores.
The hydraulic breaker and excavator do not operate to

full capacity until the oil temperature has reached at
least 60C.
WARNING!
Feeding hydraulic oil to an extremely cold hydraulic

breaker will cause internal stresses in the unit
resulting in its failure. If the breaker is used without
preheating the hydraulic oil, the breaker seals may
fracture and the diaphragm in the high-pressure
accumulator may tear. (Please observe the excavator
manufacturers regulations.)
Key Points in Tool Usage:

Follow these instructions to avoid unnecessary damage
to the tool and holder bush:
Avoid lifting, twisting and hitting.
Minimise exposure to water.
Avoid damage from striking the breaker casing off
hard objects.
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.
Avoid overheating.
Removal & Installation of the Breaker
WARNING!
The assistant must be instructed by the excavator

operator and all signals and directions agreed upon
beforehand.

The breaker should only be attached to an excavator
with sufficient load capacity. If the excavator is too
light, it may become unstable under load and fall over.

Do not touch any parts when the boom is moving.

Collect any oil which leaked out and dispose of it
correctly.

Check that the pressure relief valve on the hydraulic
system has been approved by the relevant authorities.

Check that the hydraulic pipe lines which connected
on from the carrier to the breaker.
4. Follow the reverse order when installing the breaker.
Closing
Opening
Opening and closing of the stop valve (Split type)
22
08/10/2014 15:51:21
ening
Release piston from bottom bush and push upwards

into housing using a hammer and suitable drift as
shown below.

Release any residuary gas pressure from the head
cap.

Apply grease to the inside of the bottom bush.

Connections must be sealed with clean plugs to
prevent oil leakage and dirt ingress.

The breaker must be stored in a vertical position.

Make sure the breaker can not fall.
Closing
Opening
Opening and closing of the stop valve (Coupling type)
Storage Maintenance
1. Be sure to shut the caps of the dismounted breakers
hoses.

2. Avoid unnecessary exposure to rain water store
inside or apply waterproof covering.

3. Apply enough grease to the tool.
Long Term Storage

The storage area must be dry.

Storage temperature must be above -20C (-4F)

Dismount the tool from the bottom bush.

Release the nitrogen from the head completely using
the gas valve.

23
08/10/2014 15:51:22
Travelling Position
The travelling positions are shown below. Ensure that
the breaker is not too close to the backhoe boom, when
travelling with a backhoe loader.
Backhoe Loader with breaker in travelling position
Lower the loader arm and tilt the breaker fully

backwards when travelling with a skid steer.
Skid Steer Loader with breaker in travelling position
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.
Excavator / Compact excavator with breaker in travelling

position
24
08/10/2014 15:51:22
SERVICE AND MAINTENANCE

The breaker is a precision made device. Great care must
be taken and cleanliness ensured when handling any
of the hydraulic components. Dirt is the worst enemy in
hydraulic systems!
Components must be handled carefully. Remember to
cover any cleaned and dried parts with a clean lint-free
cloth. Do not use anything other than purpose designed
cleaning agents for hydraulic parts. Never use water,
paint thinners or carbon tetrachloride.
Service Intervals
NOTE! The times given refer to machine hours while

the breaker is operated.
Every 3 hours
1. Grease the tool shank and the tool bushes.
2. Check hydraulic oil temperature, and monitor lines
and connections plus impact efficiency and
smoothness of operation.

3. Tighten any loose connections.
Every 10 hours or at least once a week
1. Remove and inspect tool pins and tool. Grind burrs
away if necessary.
2. Monitor tool and lower tool bush to verify sufficient
lubrication has been received. Increase greasing
schedule if necessary.
Every 50 hours or at least once a month
1. Check tool pin, tool shank and tool bushes for wear.
Replace out of specification components. See pages
30 - 33 for wear limits. (New upper bush required
every second time bottom bush is changed.)
2. Check hydraulic hoses. Replace if necessary.

Every 600 hours to 3000 hours
Replace components as per schedule see table on
page 26.
25
08/10/2014 15:51:22
Recommended Wear Parts Replacement Schedule

1. The parts below are expendable and require replacement at the following intervals:
Models 0060 - 1200

Description
600 Hours or
6 Months
1200 Hours or
12 Months
1800 Hours or
18 Months
2400 Hours or
24 Months
Seals
Tool Pin*
Bottom Damper*
Bottom Bush*
Hydraulic Hose**
Diaphragm***
Accumulator Body Bolt
Stopper Pin*
Shell Pad*
Upper Damper*
O-Ring of Gas Valve Set
Through Bolt Set
Upper Bush*
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. See pages 30 - 33.
3.** Check the hose condition and replace if necessary.
4.*** Diaphragm not applicable for the MGB0060, MGB0120 and MGB0200.
5. Hours: Breaker operating hours. (The operating hours are excavators operating hours that include breakers installation and
operating hours.)
Models 1550 - 7000

Description
500 Hours or
6 Months
1000 Hours or
12 Months
1550 Hours or
18 Months
2000 Hours or
24 Months
Seals
Tool Pin*
Bottom Damper*
Bottom Bush*
Hydraulic Hose**
Diaphragm
Stopper Pin*
Shell Pad*
Upper Damper*
Through Bolt Set
Upper Bush*
26
08/10/2014 15:51:22
or
s
or
s
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. See pages 30 - 33.
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
cleaning, underwater use, etc. In special applications
contact a dealer for the correct service intervals.
Risk of cavitation in pumps and in the hydraulic

breaker.
Sticky valves.
Washing the Attachment
Filter bypass opens, impurities in the oil are not

removed.
When using the breaker, dirt (mud, rock powder, etc.)

can become attached to it. Wash the outside of the
breaker with a steam washer before sending it to the
workshop. Otherwise, dirt can cause difficulties in
disassembly and assembly.
Oil too thin

Efficiency losses (internal leaks).

Damage to gaskets and seals, leaks.

Accelerated wearing of parts, because of decreased
lubrication efficiency.

Breaker strikes irregularly and slowly.

Risk of cavitation in pumps and in the hydraulic
breaker.
IMPORTANT! Plug the pressure and return line before

washing the product to prevent dirt and water ingress.
Oil & Lubrication

Breakers require the correct viscosity of hydraulic oil &
grease. The table below specifies grades for extremely
cold or hot weather. Grease the contact faces in the
lower breaker parts between the working tool and the
wear bushes.
Hydraulic Oil
High
Temperature
Low
Temperature
ISO VG 68 HV
(61.2 - 74.8 cst)
ISO VG 46 HV
(41.4 - 51.6 cst)
Correct Greasing
Grease
While greasing, the breaker must be standing upright

and resting on the tool to ensure that the grease will
penetrate downwards between the tool and the
bushes. Turn off the engine and wait 10 minutes for the
oil pressure to drop inside the breaker.
NL Gi No. 2
(265 - 295)
*Please use
MOS2 grease
inclusive of
molybdenum
IMPORTANT! Do not fill the space between the piston

and the tool with grease. A lower piston seal failure can
result and the breaker will subsequently leak oil.
Problems due to incorrect hydraulic oil viscosity

in the breaker: Oil too thick
Difficult start up.
Stiff operation.
27
08/10/2014 15:51:22
2. Insert the cartridge and turn clockwise to hand

tightness only.
Cartridge Setting
1. Push the cartridge piston cartridge spout grease
about 10mm.
VERY IMPORTANT!
10mm
Adjustment & Manual Greasing
Grease
nipple for
manual
greasing
L
Adjuster
Grease refilling port
Running time for 1
cartridge (normal
condition)
Push
10 - 20 Ton Class
2 - 4 Days
10 - 70 Ton Class
1 - 2 Days
WARNING!
If the breaker has not been used for more than 2

months, please supply enough grease manually by
grease nipple before operation.
28
08/10/2014 15:51:23
Grease Gun Application

No. of Pump / 3
Hour
cc / 3 Hour
cc / Day
Model
Multi
Mo2
Multi
Mo2
Multi
Mo2
Grease Grease Grease Grease Grease Grease
0060-0550
35
30
55
40
150
100
0800-1550
55
45
85
65
230
170
1600-1800
65
50
100
75
270
200
2000-3000
85
65
125
95
330
250
3500-4000
100
75
150
115
400
300
Models 0060-0260,0500,0550
7000
140
100
205
150
550
Models 0350, 0800, 0900
400
Tool
WARNING!
For safety reasons, the carrier must be switched

off before performing the following work:
Never use your fingers to check whether the recesses
on the working tool shaft are aligned to the slots for
the tool pin.
Models 1200-7000
Always wear protective glasses when fitting or

removing the tool, since metal splinters may fly off
when breaking out the stopper pins.
Replacement of the Tool

Models 0060-0260, 0500, 0550: Push the spring pin
back into the hole with the pin punch.
Clean away any dirt adhering to the working tool in

the insert zone.
Models 0350, 0800-7000: Knock out the stopper pin

and rubber plug for the upper tool pins with a pin
punch. Knock the tool pin out using a pin punch.
Lubricate to the contact faces in the lower breaker

area between the working tool and wear bushes.
Replace with new tool. In the case of tool pin wear

outside of service limits, (see page 30) both sides may
be used.
The tool should only be fitted correctly.
29
08/10/2014 15:51:24
When changing tool pin direction, place pin

with this surface on tool side
Remove burrs and swelling

with grinder or the like
Tool Pin
When tool pins become excessively deformed, tool
replacement becomes difficult. Therefore, every 100 to
150 hours of operation, change the face of each pin.
Tool Selection
By Rock Type
Asphalt
Concrete
Lime-Stone
SandStone
Granite
Basalt
Moil
Chisel
Blunt
Primary
Breaking
By Job Application
Secondary
Breaking
Hard Rock
Removal
Soft Material
& Rock Removal
Demolition
Moil
Chisel
Blunt
Note:
1. Highly recommended
2. Selectively applicable
3. Please consult with the dealer when selecting tools.
30
08/10/2014 15:51:24

Standard Value (A)
mm
inch
Model
Wear Limits (B)

mm
inch
0060
22
0.87
20
0.79
0120
25
0.98
23
0.91
0200
30
1.18
28
1.10
0260
36
1.42
34
1.34
0350
42
1.65
40
1.57
37.5
1.48
35.5
1.40
0800
36
1.42
34
1.34
0900
50
1.97
47
1.85
1200 - 1600
70
2.76
67
2.64
1800
80
3.15
77
3.03
2000 - 2500
95
3.74
92
3.62
3000
97
3.82
94
3.70
3500 - 4000
100
3.94
96
3.78
7000
137
5.39
132
5.20
0500 - 0550
Models 0060-0260, 0500-0800
Models 0350, 0900-7000
Tool Wear Limits

Model
Standard Value
mm
inch
Wear Limits (X)

mm
inch
Wear Limits (Y)

mm
inch
0060
40
1.57
38
1.50
36
1.42
0120
45
1.77
43
1.69
41
1.61
0200
57
2.24
55
2.17
53
2.09
0260
70
2.76
68
2.68
66
2.60
0350
75
2.95
73
2.87
71
2.80
0500
80
3.07
78
3.07
76
2.99
0550
90
3.46
88
3.46
86
3.39
0800
95
3.66
93
3.66
91
3.58
0900
105
4.13
103
4.06
101
3.98
1200
115
4.53
113
4.45
111
4.37
1550
125
4.84
123
4.84
121
4.76
1600
135
5.31
133
5.24
131
5.16
1800
135
5.31
133
5.24
131
5.16
2000
145
5.71
143
5.63
141
5.55
2500
150
5.91
148
5.63
146
5.75
3000
155
6.10
153
6.02
151
5.94
3500
165
6.50
163
6.42
161
6.34
4000
175
6.89
172
6.77
170
6.69
7000
205
8.07
202
7.95
200
7.87
31
08/10/2014 15:51:24
Upper Damper Wear Limits

Model
Standard Value
mm
inch
Wear Limits (B)

mm
inch
Mod
0120 - 0200
54
2.13
52
2.05
0060
0260 - 0550
78
3.07
75
2.95
0120
0800 - 0900
100
3.94
96
3.78
1600
1200 - 1600
110
4.33
106
4.17
2000
0800 - 4000
125
4.92
121
4.76
3000
7000
147
5.79
142
5.59
7000
Bottom Damper Wear Limits

Model
Standard Value
mm
inch
Wear Limits (C)

mm
inch
0120 - 1600
20
0.79
18
0.71
1800 - 4000
25
0.98
22
0.87
7000
35
1.38
31
1.22
Upper Bush Wear Limits

Model
Wear Limits (D)

mm
inch
Wear Limits (E)

mm
inch
0060 - 0260
0.20
0350
0.20
13
0.51
0500
0.24
13
0.51
0550
0.24
15
0.59
0800
0.24
9*
0.35
0900
0.24
14
0.55
1200
0.24
0.35
1550
0.24
0.31
1600
0.28
15
0.59
1800
0.28
0.31
2000
0.31
0.31
2500
0.31
16
0.63
3000
0.35
13
0.51
3500
0.35
15
0.59
4000
0.35
22
0.87
7000
10
0.39
26
1.02
32
08/10/2014 15:51:25
Bottom Bush Wear Limits

Wear Limits (F)
Model
mm
inch
0060 - 0350
0.12
0120 - 1550
0.16
1600 - 1800
0.20
2000 - 2500
0.24
3000 - 4000
0.28
7000
0.31
Stopper Pin Wear Limits

Standard Diaphragm (G)
mm
inch
Model
Wear Limits (H)

mm
inch
0060 - 0260
10
0.39
0.31
0350
15
0.59
13
0.51
0500 - 0550
10
0.39
0.31
0800 - 2000
17.5
0.69
15.5
0.61
2500 - 3000
21.5
0.85
19.5
0.77
3500 - 7000
27.5
1.08
25.5
1.00
Shell Pad Wear Limits
Model
Standard Value
mm
inch
Wear Limits (J)

mm
inch
Standard Value
mm
inch
Wear Limits (K)

mm
inch
0120
106
4.17
109
4.29
106
4.17
109
4.29
0200
114
4.49
117
4.61
135
5.31
138
5.43
0260
132
5.20
135
5.31
142
5.59
145
5.71
0350
152
5.98
155
6.10
162
6.38
165
6.50
0500
167
6.57
170
6.69
172
6.77
175
6.89
0550
177
6.97
180
7.09
177
6.97
180
7.09
0800
202
7.95
205
8.07
202
7.95
205
8.07
33
08/10/2014 15:51:25

Model
Standard Value
mm
inch
Wear Limits (J)

mm
inch
Standard Value
mm
inch
Wear Limits (K)

mm
inch
0900
222
8.74
225
8.86
222
8.74
225
8.86
1200
232
9.13
235
9.25
232
9.13
235
9.25
1550
252
9.92
255
10.04
252
9.92
255
10.04
1600
252
9.92
255
10.04
252
9.92
255
10.04
1800
272
10.71
275
10.83
272
10.71
275
10.83
2000
282
11.10
285
11.22
282
11.10
285
11.22
2500
302
11.89
305
12.01
302
11.89
305
12.01
3000
322
12.68
325
12.80
322
12.68
325
12.80
3500
332
13.07
335
13.19
332
13.07
335
13.19
4000
342
13.46
345
13.58
342
13.46
345
13.58
7000
408
16.06
411
16.18
422
16.61
425
16.73
Examples of Mis-Handling
Cause of Tool Damage

1. Side pressure due to mis-use; incorrect driving angle,
use as a lever or using the breaker to pull heavy
objects.

2. Blank fire leading to the damage on the tool pin.

3. Low temperature causing the tool to be more
susceptible to fatigue failure.

4. Overheating by friction caused by poor lubrication or
excessive bending.

5. Excessive wear of the bottom bush allowing the
piston to strike the tool at an angle. This causes
damage on contact faces of the tool and piston.
Leverage
Bending by High Pressure
Using
machine
to pull
Bending the tool
High pressure and friction

bending surface of tool shank
34
08/10/2014 15:51:25
)
h
Specifications
SPECIFICATIONS
Description
Unit
0060
0120
0200
0260
Top Mounting
Type
kg
55
120
187
260
lb
121
265
412
573
Side Mounting
Type
kg
59
165
225
lb
130
363
496
Top Mounting
Type
mm
1,117
1,135
1,450
1,513
inch
43.9
44.69
57.09
59.57
mm
926
1,252
1,315
inch
36.45
49.29
59.57
mm
40
45
57
70
inch
1.57
1.77
2.24
2.76
kg/cm
175
175
175
175
Psi
2500
2,500
2,500
2,500
kg/cm
60 - 130
90 - 120
90 - 120
110 -165
Psi
870 - 1885
1,280 - 1,700
1,280 - 1,700
1,565 - 2,350
lpm
12 - 25
12 - 25
23 - 70
29 - 65
gpm
3.17 - 6.60
3.17 - 6.60
6.07 - 18.48
7.66 - 17.17
Low Speed
bpm
800 - 1200
550 - 1,000
600 - 1,500
380-1,000
High Speed
bpm
kg/cm
10 - 14
10 - 14
14 - 16
10-14
Psi
142 - 199
142 - 199
199 - 228
142 - 199
kg/cm
40 - 50
Psi
569 - 711
ton
0.5 - 2
0.8 - 2.5
1.5 - 4.0
3 - 6.5
lb
1,110 - 4,400
1,760 - 5,500
3,300 - 8,800
6,600 - 14,300
Operating
Weight*
Overall
Length
Side Mounting
Type
Tool Diameter
2nd Relief Setting Pressure**
Operating Pressure
Oil Flow
Blow Rate
Back Head Gas Pressure

Accumulator Gas Pressure
Suitable Carrier
Note:
1. * Operating weight excluding quick coupler and pins

2. ** 2nd relief valve pressure guide based on carrier
3. 0500 - 0800 are top mounting type only
35
08/10/2014 15:51:25
Specifications
Description
Unit
0350
0500
0550
0800
0900
Top
Mounting
Type
kg
330
495
545
800
900
lb
728
1,091
1,202
1,764
1,984
Side
Mounting
Type
kg
260
830
lb
573
1,830
Top
Mounting
Type
mm
1,639
1,894
2,062
2,125
2,234
inch
64.53
74.57
81.18
83.66
87.95
mm
1,342
1,969
inch
52.83
77.52
mm
75
80
90
95
105
inch
2.95
3.15
3.54
3.74
4.13
kg/cm
175
175
175
210
210
Psi
2,500
2,500
2,500
3,000
3,000
kg/cm
120 - 165
140 - 170
140 - 170
140 - 180
140 - 190
Psi
1,700 - 2,350
1,990 - 2,420
1,990 - 2,420
1,990 - 2,560
1,990 - 2,700
lpm
34 - 76
38 - 85
42-94
63 - 102
68 - 119
gpm
8.98 - 20.07
10.03 - 22.45
11.09 - 24.83
16.64 - 26.94
17.96 - 31.43
Low Speed
bpm
380 - 900
400 - 800
350 - 700
350 600
350 - 550
High Speed
bpm
600 - 1,100
490 - 1,000
600 - 900
600 - 900
Back Head Gas

Pressure
kg/cm
16-18
10 - 14
10 - 14
10 - 14
10 - 14
Psi
228 - 256
142 - 199
142 - 199
142 - 199
142 - 199
Accumulator Gas
Pressure
kg/cm
40 - 50
40 - 50
40 - 50
55 - 60
55 - 60
Psi
569 - 711
569 - 711
569 - 711
782 - 853
782 - 853
ton
4.5 - 8
4.5 - 8
6 - 10
8 - 12.5
10-15
lb
9,900 -17,600
9,900 - 17,600
13,200 - 22,000
17,600 - 27,500
22,000 - 33,000
Operating
Weight*
Overall
Length
Side
Mounting
Type
Tool Diameter
2nd Relief Setting
Pressure**
Operating Pressure
Oil Flow
Blow Rate
Suitable Carrier
Note:
3. 0500 - 0800 are top mounting type only
36
08/10/2014 15:51:26
700
.43
Specifications
Description
Operating
Weight*
Overall
Length
Unit
1200
1550
1600
1800
2000
Top
Mounting
Type
kg
1,150
1,450
1,580
1,800
2,000
lb
2,535
3,197
3,483
3,968
4,409
Side
Mounting
Type
kg
1,050
1,585
1,745
1,930
lb
2,315
3,494
3,847
4,255
Top
Mounting
Type
mm
2,442
2,522
2,589
2,775
2,906
inch
96.14
99.29
101.93
109.25
114.41
mm
2,032
2,293
2,418
2,503
inch
80.00
90.28
95.20
98.54
mm
115
125
135
135
145
inch
4.53
4.92
5.31
5.31
5.71
kg/cm
210
210
210
210
210
Psi
3,000
3,000
3,000
3,000
3,000
kg/cm
140 - 190
150 - 190
160 - 190
160 - 190
160 - 190
Psi
1,990 - 2,700
2,130 - 2,700
2,275 - 2,700
2,275 - 2,700
2,275 - 2,700
lpm
85 - 127
95 - 131
115 - 155
119 - 161
127 - 178
gpm
22.45 - 33.54
25.09 - 34.60
30.37 - 40.94
31.43 - 42.53
33.54 - 47.02
Low Speed
bpm
320 - 550
320 - 500
320 - 480
340 - 450
270 - 400
High Speed
bpm
400 - 700
400 - 650
400 - 600
420 - 550
330 - 500
Side
Mounting
Type
Tool Diameter
2nd Relief Setting
Pressure**
Operating Pressure
Oil Flow
Blow
Rate
kg/cm
14 - 16
14 - 16
14 - 16
14 - 16
14 - 16
Back Head Gas

Pressure
Psi
199 - 228
199 - 228
199 - 228
199 - 228
199 - 228
kg/cm
55 - 60
55 - 60
55 - 60
55 - 60
55 - 60
Accumulator Gas
Pressure
Psi
782 - 853
782 - 853
782 - 853
782 - 853
782 - 853
ton
12-18
16 - 22
18 - 24
20 - 26
24 - 30
lb
26,500 - 39,700
35,200 - 48,500
39,700 - 52,900
44,100 - 57,300
52,900 - 66,100
,000
Suitable Carrier
Note:

3. 1550 is top mounting type only
37
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Specifications
Unit
2500
3000
3500
4000
7000
Top
Mounting
Type
kg
2,400
2,700
3,300
3,800
7,000
lb
5,291
5,952
7,275
8,378
15,432
Side
Mounting
Type
kg
2,410
2,780
2,910
3,780
lb
5,313
6,129
6,415
8,333
Top
Mounting
Type
mm
3,016
3,085
3,508
3,580
4,256
inch
118.74
121.46
138.11
140.94
167.56
mm
2,564
2,670
2,832
3,013
inch
100.94
105.12
111.50
118.62
mm
150
155
165
175
205
inch
5.91
6.10
6.50
6.89
8.07
kg/cm
210
230
230
210
250
Psi
3,000
3,300
3,300
3,000
3,570
kg/cm
160 - 190
160 - 190
150 - 190
150 - 190
170 - 210
Psi
2,275 - 2,700
2,275 - 2,700
2,130 - 2,700
2,130 - 2,700
2,420 - 3,000
lpm
154 - 204
170 - 238
187 - 250
204 - 272
350 - 420
gpm
40.41 - 53.89
44.90 - 62.87
49.40 - 66.04
53.89 - 71.85
92.46 - 110.95
Low Speed
bpm
250 - 380
230 - 400
230 - 345
230 - 330
280 - 350
High Speed
bpm
300 - 450
270 - 470
270 - 410
270 - 500
320 - 520
Back Head Gas

Pressure
kg/cm
14 - 16
14 - 16
10 - 14
14 - 16
16 - 18
Psi
199 - 228
199 - 228
142 - 199
199 - 228
228 - 256
Accumulator Gas
Pressure
kg/cm
55 - 60
55 - 60
55 - 60
55 - 60
55 - 60
Psi
782 - 853
782 - 853
782 - 853
782 - 853
782 - 853
ton
25 - 36
28 - 42
34 - 50
40 - 60
60 - 100
lb
55,100 - 79,400
61,700 - 92,600
75,000 - 110,200
88,200 - 132,300
132,300 - 220,500
Description
Operating
Weight*
Overall
Length
Side
Mounting
Type
Tool Diameter
2nd Relief Setting
Pressure**
Operating Pressure
Oil Flow
Blow
Rate
Suitable Carrier
Note:
3. 7000 is top mounting type only
38
08/10/2014 15:51:26
Specifications
Skid Steer Loader Specifications

Unit
2500
3000
3500
4000
7000
Top
Mounting
Type
kg
2,400
2,700
3,300
3,800
7,000
lb
5,291
5,952
7,275
8,378
15,432
Side
Mounting
Type
kg
2,410
2,780
2,910
3,780
lb
5,313
6,129
6,415
8,333
Top
Mounting
Type
mm
3,016
3,085
3,508
3,580
4,256
inch
118.74
121.46
138.11
140.94
167.56
mm
2,564
2,670
2,832
3,013
inch
100.94
105.12
111.50
118.62
mm
150
155
165
175
205
inch
5.91
6.10
6.50
6.89
8.07
kg/cm
210
230
230
210
250
Psi
3,000
3,300
3,300
3,000
3,570
kg/cm
160 - 190
160 - 190
150 - 190
150 - 190
170 - 210
Psi
2,275 - 2,700
2,275 - 2,700
2,130 - 2,700
2,130 - 2,700
2,420 - 3,000
lpm
154 - 204
170 - 238
187 - 250
204 - 272
350 - 420
gpm
40.41 - 53.89
44.90 - 62.87
49.40 - 66.04
53.89 - 71.85
92.46 - 110.95
Low Speed
bpm
250 - 380
230 - 400
230 - 345
230 - 330
280 - 350
High Speed
bpm
300 - 450
270 - 470
270 - 410
270 - 500
320 - 520
Back Head Gas

Pressure
kg/cm
14 - 16
14 - 16
10 - 14
14 - 16
16 - 18
Psi
199 - 228
199 - 228
142 - 199
199 - 228
228 - 256
Accumulator Gas
Pressure
kg/cm
55 - 60
55 - 60
55 - 60
55 - 60
55 - 60
Psi
782 - 853
782 - 853
782 - 853
782 - 853
782 - 853
ton
25 - 36
28 - 42
34 - 50
40-60
60 - 100
lb
55,100 - 79,400
61,700 - 92,600
75,000 - 110,200
88,200 - 132,300
132,300 - 220,500
Description
Operating
Weight*
Overall
Length
Side
Mounting
Type
Tool Diameter
2nd Relief Setting
Pressure**
00
Operating Pressure
.95
Oil Flow
Blow
Rate
0,500
Suitable Carrier
Note:

3. Skid steer loader is top mounting type only
4. When mounting on New Holland Skid steer loader charge N2 gas at 8-10 kg/cm
39
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Notes
40
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SERVICE MANUAL
HYDRAULIC BREAKER
08/10/2014 15:51:26
42
08/10/2014 15:51:26
Service Manual Foreword
SERVICE MANUAL FOREWORD

This Service Manual contains specifications,
descriptions, repair instructions, drawings and diagrams
for the hydraulic breaker.
WARNING!
This warning symbol means risk of fatalities or

personal injury if the instructions are not followed.
Also read through and follow the instructions in the

Safety Section in the service manual for each machine
type.
All lifting devices such as slings, straps, ratchet blocks,
etc. must comply with governing national regulations for
lifting devices.
We will not accept any responsibility if tools or work
methods other than those described in this publication
are used.
All information and data contained in this manual are
current and valid at time of publication.
We reserve the right to modify specifications and
equipment without prior notice.
43
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Service Manual Table of Contents
SERVICE MANUAL TABLE OF CONTENTS

SERVICE MANUAL FOREWORD
43
CONTENTS
44
HYDRAULIC BREAKER GENERAL

INFORMATION
Internal Control Valve System
Operating Principle (0120 - 0200)
SERVICING
Inspection & Maintenance
Bolts
Gas Pressure & Charging Nitrogen Gas
Replaceable Wear Parts
Wear Limits
Setting of 2nd Relief Valve Pressure on
Excavator
Oil Temperature
Accumulator (0260 - 7000)
Oil Leakage
The Contamination of Working Oil
Mounting & Installation of Hydraulic Breaker
Precautions of Installation
Hydraulic System
Hydraulic Pipe Lines & Controls
Disassembly
I. Housing Disassembly
A. Top Mount Housing
B. Side Mount Housing
II. Discharge of Nitrogen Gas in the Back Head

III. Power Cell Disassembly
Reassembly
45
I. Power Cell Assembly
45
A. Accumulator & Cylinder Assembly
46
B. Front Head Assembly
46
C. Piston & Cylinder Bush Assembly
48
D. Back Head Assembly
50
II. Housing Assembly
50
50
50
Gas Charging Procedure - Back Head
51
Gas Charging Procedure - Accumulator
52
Repair of Parts
55
Maintenance Carried out by the Operator
55
TROUBLESHOOT GUIDE
55
Malfunctions
55
Oil Leakage
55
Poor Operation of Breaker
56
Breaker Tool Failure Caused by Incorrect

Operation / Application
56
Torque
57
Torque for each Parts
58
Wear Parts Replacement Recommendation
58
62
62
68
68
68
70
70
72
76
76
77
79
80
83
86
87
87
89
90
91
92
93
94
58
58
58
60
44
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Hydraulic Breaker General Information
HYDRAULIC BREAKER GENERAL INFORMATION

62
62
68
68

The breaker consists of five main sections: Cylinder, Piston, Control Valve, Front Head and Back Head.
1. The cylinder contains the piston and valve.
2. Four through bolts are assembled and hold the cylinder and back head together with front head.
68
3. Piston strikes the tool by oil and gas pressure.
70
4. Control valve inside cylinder regulates piston movement.
70
5. Tool pins inside the front head retain the tool.
72
6. Back head contains charged Nitrogen gas.
76
76
0060, 0200
77
0260 - 7000
Through Bolt
79
Back Head
80
83
Control Valve
86
Cylinder
87
Piston
87
Accumulator
89
90
Front Head
91
92
Tool Pin
93
94
Tool
45
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Internal Control Valve System

ICVS technology is widely available for skid steer
loaders plus backhoe loaders. Currently breakers for
0.8-70 ton excavators are also available, the main
applications being destruction of hard rock and paved
roads plus trenching, etc.
1. Compared with breakers featuring external valves,
new valve breakers increase impact energy by
5 - 10 %.
2. (When fitted) The high-pressure accumulator
eliminates pressure fluctuation and protects
equipment such as hydraulic pumps & MCV on
excavator. Impact power is increased;
Increased operating pressure by accumulator
makes energy more efficient (0260 - 7000).
A heavier weight piston generates more powerful
impact.
Piston stroke is increased for maximum impact
power.
High Pressure
Low Pressure (return
line to the tank)
3. Reduced part count to control maintenance costs.
Raising the Piston
4. Simple and good-looking design.
High pressure causes piston P to rise, compressing

gas in chamber B and pumping low pressure oil in the
upper shoulder area D back to tank.
5. Internal control valve system breakers are more

efficient, stay cooler, reduce speed fluctuations and
increase breaking power.
6. Damage resistance is improved during breaking of
hard rocks as well as noise reduction.
7. Larger diameter through bolts help minimise cylinder
/ piston damage through blank fire.
8. Stroke adjuster allows control of blow frequency and
impact power (0500 - 7000).

Start Up
The cycle begins with high pressure oil from the
excavator entering A and acting on the bottom area
C of piston P. Valve E remains down. Low
pressure oil in upper shoulder area D is connected to
the return line.
High Pressure
line to the tank)
46
Operating principle regarding: 0060- 0200
08/10/2014 15:51:27
Piston Stroke
Impact Stroke
The lower shoulder G opens channel H and high

pressure lifts control valve E. At its upper limit
the control valve directs high pressure to the upper
shoulder area D of the piston. The net force of
hydraulic pressure on the upper shoulder plus gas
pressure from chamber B combine to drive piston P
down.
Piston P is powered onto tool T. During piston

stroke pilot channel L is opened to the return line
and control valve E drops releasing high pressure in
the upper shoulder area D to tank. Low pressure is
restored for the start-up position.
High Pressure
line to the tank)
Operating principle regarding: 0060 - 0200
47
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Operating Principle (0260-7000)

Raising the Piston
Start Up
High pressure causes piston P to rise, compressing

gas in chamber B and pumping low pressure oil in the
upper shoulder area D back to tank. Accumulator J
becomes charged.
The cycle begins with high pressure oil from the

excavator entering A and acting on the bottom area
C of piston P and accumulator J. Valve E
remains down. Low pressure oil in upper shoulder
area D is connected to the return line.
High Pressure
line to the tank)
48
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Piston Stroke
Impact Stroke
The lower shoulder G opens channel H and high

pressure lifts control valve E. At its upper limit
the control valve directs high pressure to the upper
shoulder area D of the piston. The net force of
hydraulic pressure from the excavator (aided by the
accumulator) on the upper shoulder, plus gas pressure
from chamber B combine to drive piston P down
Piston P is powered onto tool T. During piston

stroke pilot channel L is opened to the return line
and control valve E drops releasing high pressure in
the upper shoulder area D to tank. Low pressure is
restored for the start-up position.
High Pressure
line to the tank)
49
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Servicing
Bolts
SERVICING
Bolt torque should be checked after long periods

of inactivity, and regularly during frequent use. If
retightening is required all bolts should be released
and re-torqued to ensure even clamping. If bolts are
frequently found to be loose, request help from Product
Support.
Inspection & Maintenance

The breaker is designed for breaking concrete, road
surface / asphalt, hard or frozen ground. It is also
suitable for light trenching and benching applications or
for ground compacting. It can also be used for breaking
small and soft boulders.
Gas Pressure & Charging Nitrogen Gas

The hydraulic breaker operates with hydraulic oil & gas
pressure.
WARNING!
The back head may spring out very suddenly if gas

pressure is not vented before removal!
Be sure to release gas pressure via the back head
gas valve before disassembly.
Be sure to completely tighten the through bolts to
the specified torque before gas charging.
WARNING!
Fill with nitrogen only. Filling with air or oxygen runs the
Risk Of An Explosion!
Maintain gas pressure within the optimum range to
allow high performance without overloading the
breaker.
The back head is filled with Nitrogen. Discharge gas

pressure before disassembly using gas charge kit as
explained on page 62.
Different working conditions require specific gas

pressures for optimum breaker performance.
Check the O-ring if gas pressure does not appear to
be maintained.
If hydraulic oil leaks into back head from the cylinder,
replace the gas seal or O-rings in the cylinder bush.
Check for scratches on the piston.
The pressure in the back head should be set
according to the chart as follows:
Gas Pressure
Back Head
Recharging the back head may cause the tool to spring

out. Do not stand in front of the tool to avoid accidents.
0260-0500 for Skid Steer Loader

10-12 kg/cm
* CAUTION: When mounting on New Holland Skid Steer

Loader charge N2 gas at 8-10 kg/cm.
50
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Servicing
Gas Pressure
0060, 0260, 0500-0900, 3500
0200, 1200-3000, 4000
0350, 7000
10 - 14 kg/cm
14 - 16 kg/cm
16 - 18 kg/cm
Back Head
* Gas pressure should only be checked with the tool projecting from the bottom bush to its full extent.
Gas Pressure
0260, 0500-0900, 3500
0200, 1200-3000, 4000
0350, 7000
Accumulator
40 - 50 kg/cm
55 - 60 kg/cm
75 kg/cm
Return line: 20 kg/cm
* Gas pressure should only be checked with the tool projecting from the bottom bush to its full extent.
Replaceable Wear Parts

The following items are considered as wear parts.
Replacement is highly recommended when damaged or
worn. It is recommended the user stocks wear parts as
follows:

1. Breaker tool

2. Bottom bush and Upper bush

3. Tool pins / stopper pin / rubber plug

4. Hydraulic seals

5. Through bolts

6. Hydraulic hoses
When changing tool pin direction,

place pin with this surface on tool side
Replace hydraulic seals every 500 - 600 hours of actual

operation or every 6 months in storage.

0060 - 1200: every 600 hours or 6 months

1550 - 7000: every 500 hours or 6 months
Remove burrs and swelling

with grinder or the like
Tool pins: Excessive damage to the tool pin makes tool

replacement difficult. Inspect every 100 to 150 hours of
operation and change the face of each pin that comes
into contact with the tool if required (both faces of the
pin can be used).
If none genuine tools are used, we cannot guarantee
performance of breaker parts.
51
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Servicing

Standard Value (A)
Model
Wear Limits (B)
mm
inch
mm
inch
0060
22
0.87
20
0.79
0120
25
0.98
23
0.91
0200
30
1.18
28
1.10
0260
36
1.42
34
1.34
0350
42
1.65
40
1.57
37.5
1.48
35.5
1.40
0800
36
1.42
34
1.34
0900
50
1.97
47
1.85
1200 - 1600
70
2.76
67
2.64
1800
80
3.15
77
3.03
2000 - 2500
95
3.74
92
3.62
3000
97
3.82
94
3.70
3500 - 4000
100
3.94
96
3.78
7000
137
5.39
132
5.20
0500 - 0550
0060 - 0260,
0500 - 0800
0350,
0900 - 7000
Tool Wear Limits

Standard Value
Wear Limits (X)
Wear Limits (Y)
mm
inch
mm
inch
mm
inch
0060
40
1.57
38
1.50
36
1.42
0120
45
1.77
43
1.69
41
1.61
0200
57
2.24
55
2.17
53
2.09
0260
70
2.76
68
2.68
66
2.60
0350
75
2.95
73
2.87
71
2.80
0500
80
3.07
78
3.07
76
2.99
0550
90
3.46
88
3.46
86
3.39
0800
95
3.66
93
3.66
91
3.58
0900
105
4.13
103
4.06
101
3.98
1200
115
4.53
113
4.45
111
4.37
1550
125
4.84
123
4.84
121
4.76
1600
135
5.31
133
5.24
131
5.16
1800
135
5.31
133
5.24
131
5.16
2000
145
5.71
143
5.63
141
5.55
2500
150
5.91
148
5.63
146
5.75
3000
155
6.10
153
6.02
151
5.94
3500
165
6.50
163
6.42
161
6.34
4000
175
6.89
172
6.77
170
6.69
7000
205
8.07
202
7.95
200
7.87
Model
52
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Servicing
Upper Damper Wear Limits

Model
0260,
0800
0120 - 0200
0260 - 0550
0800 - 0900
1200 - 1600
1800 - 4000
7000
Standard Value
mm
54
78
100
110
125
147
inch
2.13
3.07
3.94
4.33
4.92
5.79
Wear Limits (B)

mm
52
75
96
106
121
142
inch
2.05
2.95
3.78
4.17
4.76
5.59
Bottom Damper Wear Limits

Model
7000
0120 - 1600
1800 - 4000
7000
Standard Value
mm
inch
20
25
35
0.79
0.98
1.38
Wear Limits (C)

mm
inch
18
22
31
0.71
0.87
1.22
Upper Bush Wear Limits

Model
0060 - 0260
0350
0500
0550
0800
0900
1200
1550
1600
1800
2000
2500
3000
3500
4000
7000
Wear Limits (D)

mm
inch
5
5
6
6
6
6
6
6
7
7
8
8
9
9
9
10
0.20
0.20
0.24
0.24
0.24
0.24
0.24
0.24
0.28
0.28
0.31
0.31
0.35
0.35
0.35
0.39
Wear Limits (E)

mm
inch
13
13
15
9*
14
9
8
15
8
8
16
13
15
22
26
0.51
0.51
0.59
0.35
0.55
0.35
0.31
0.59
0.31
0.31
0.63
0.51
0.59
0.87
1.02
53
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Servicing
Bottom Bush Wear Limits

Wear Limits (F)
Model
mm
inch
3
4
5
6
7
8
0.12
0.16
0.20
0.24
0.28
0.31
Standard Diaphragm (G)

mm
inch
Wear Limits (H)

mm
inch
0060 - 0350
0120 - 1550
1600 - 1800
2000 - 2500
3000 - 4000
7000
Stopper Pin Wear Limits

Model
0060 - 0260
0350
0500 - 0550
0800 - 2000
2500 - 3000
3500 - 7000
10
15
10
17.5
21.5
27.5
0.39
0.59
0.39
0.69
0.85
1.08
8
13
8
15.5
19.5
25.5
0.31
0.51
0.31
0.61
0.77
1.00

Model
Standard
Value
mm
inch
Wear Limits
(J)
mm
inch
Standard
Value
mm
inch
Wear Limits
(K)
mm
inch
0120
0200
0260
0350
0500
0550
0800
0900
1200
1550
1600
1800
2000
2500
3000
3500
4000
7000
106
114
132
152
167
177
202
222
232
252
252
272
282
302
322
332
342
408
109
117
135
155
170
180
205
225
235
255
255
275
285
305
325
335
345
411
106
135
142
162
172
177
202
222
232
252
252
272
282
302
322
332
342
422
109
138
145
165
175
180
205
225
235
255
255
275
285
305
325
335
345
425
4.17
4.49
5.20
5.98
6.57
6.97
7.95
8.74
9.13
9.92
9.92
10.71
11.10
11.89
12.68
13.07
13.46
16.06
4.29
4.61
5.31
6.10
6.69
7.09
8.07
8.86
9.25
10.04
10.04
10.83
11.22
12.01
12.80
13.19
13.58
16.18
4.17
5.31
5.59
6.38
6.77
6.97
7.95
8.74
9.13
9.92
9.92
10.71
11.10
11.89
12.68
13.07
13.46
16.61
4.29
5.43
5.71
6.50
6.89
7.09
8.07
8.86
9.25
10.04
10.04
10.83
11.22
12.01
12.80
13.19
13.58
16.73
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Servicing
Setting of 2nd Relief Valve Pressure on Excavator

Each breaker has different working pressure range depending on the class. Higher excavator working pressures than
that specified for the breaker can cause problems with the breaker and excavator. Please request assistance from
your excavator dealer with setting of 2nd relief valve pressure.
Description
Relief Valve
Setting Pressure
Description
Relief Valve
Setting Pressure
Unit
0060 - 0550
0800 - 2500
3000 - 3500
4000
7000
kg/cm
psi
175
2,500
210
3,000
230
3,300
210
3,000
250
3,570
Unit
Skid Steer Loader
kg/cm
psi
230
3,300
Oil Temperature
The oil temperature varies according to working
condition but it is usually 50-80C. If it rises above 80C
accumulator rubber and O-ring life may be reduced.
In the case of a significant leak, check and replace

seals applying working oil to the seal kit and seal
groove.
Be cautious of the following to avoid the rise of oil

temperature:
The following should be inspected when replacing

seals:
1. Avoid continually striking the same point for over 30

seconds.
1. Ensure seals are not scratched on assembly and are

correctly pressed into the seats.
2. The volume of oil required by the breaker for any

given pressure setting is constant. Blow rate is
maintained regardless of engine speed, with excess
oil flowing out via the relief valve. Unnecessary
engine RPM increase will not increase breaker power
only result in oil temperature increase.
2. Work in a clean area and keep components free of

debris.
3. If seals have become damaged, check piston surface
for scratches.
4. Damage to the seals within the cylinder bush will
generate major oil leakage. Should this happen
replace seals & O-ring as a set.
3. Keep the oil cooler clean to avoid overheating.
Accumulator (0260 - 7000)
Request the service of Product Support if oil leaks

persist after replacing seals.
Low accumulator gas pressure can cause big pulsations

of the high pressure hose. Refill nitrogen gas to the
specified pressure if required. Should violent pulsations
continue and if gas pressure is not maintained, check
for oil leaks around the accumulator. Contact Product
Support for Diaphragm & O-ring checks plus the
accumulator charging valve. After replacement and
inspection, the fixing socket bolts require setting with a
torque wrench.
The Contamination of Working Oil

Contamination of working oil can cause problems with
the control valve and can damage the piston. Keep the
working oil clean. Replace the excavator oil filter every
100 hours and change the working oil every 600 hours.
When installing a breaker on an old excavator, replace
and recharge the working oil if necessary.
Oil Leakage
Inspect joints for oil leaks. Minor leakage between tool
and bottom bush is normal and helps lubricate the tool.
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Servicing
Mounting & Installation of Hydraulic Breaker

General view of breaker installed to carrier
High Pressure
Low Pressure
The hydraulic breaker is powered by the hydraulic

system of the machine on which it is mounted, such
as excavator, mini-excavators, backhoe loader etc.
To enable carriers to operate with such attachments,
the hydraulic power system has to be converted
accordingly.
Precautions of Installation
The breaker requires proper oil flow and pump pressure.

Pressure settings for specific breakers are listed below,
which is 10 kg/cm less than main relief pressure.
Select level ground that is free from mud, dust and dirt.
A service shop is most suitable.
When bucket and breaker are interchanged regularly,

the hydraulic breaker is fitted to a carrier via two pins
for easy replacement. However, as the hydraulic circuit
is prone to contamination, removal and installation
should be done using the following procedure;
Position the carrier as shown in the diagram to the right.

Stop the engine and turn off the main switch. If the
hydraulic tank of the carrier is pressurized, vent the air
from the oil tank. The breaker and bucket can now be
interchanged.
0060 - 0550: 175 kg/cm

0800 - 2500: 210 kg/cm
3000 - 3500: 230 kg/cm
4000: 210 kg/cm
7000: 250 kg/cm
Skid steer loader: 230 kg/cm
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Servicing
CAUTION: The stop valve off must be shut off before removing the breaker from excavator.
Hydraulic System
Proper Input Oil Flow

This must be checked with a flow meter at the time of
installation and the machines flow and pressure
adjusted accordingly.
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CAUTION:
The blow rate of the breaker can be adjusted using the

following procedure:
Check that the excavator has a suitable hydraulic

system, with the correct diameter hydraulic lines.
Check the connections on the hydraulic breaker and
the breaker hoses.
The connecting threads must be undamaged and free
of sand or similar foreign bodies.
Check the pressure relief valve on the hydraulic
system has been approved by the relevant authorities.
Ensure that the pressure relief valve has been set
correctly, i.e. to the maximum permissible operating
pressure of the hydraulic breaker. (Operating pressure
+ min 30 kg/cm)
As the hydraulic circuit varies with the carrier,
hydraulic pressure, oil capacity pressure loss, etc.
of the carrier, this needs to be checked by a Product
Support Engineer at the time of first installation.
As the hydraulic pipe lines (hoses, pipes and fittings)
are made of materials carefully selected for durability,
use genuine parts when replacing the parts.
Hydraulic oil becomes very hot during operation.
1. Release the nut of adjuster.

2. High speed (Low power): turn adjuster
counter-clockwise. (turn 2 turns)
Low speed (High power): turn adjuster clockwise.
(fully tighten)
3. Tighten the nut of the adjuster after setting.
Hose Size
Model
Speed
Up
Hose Size
0060 - 0260
0350 - 0900
1200 - 1800
2000 - 4000
7000
Speed
Down
5mm L-wrenches
1
1
1
Disassembly
I. Housing Disassembly
Hydraulic Pipe Lines & Controls

1. The breaker uses the following devices / equipment
of the carrier:
Hydraulic oil tank.
Oil pump.
Hydraulic control valve (when a spare valve is
available in control valve bank of carrier.)
WARNING!
Use slings / chains of the correct capacity to lift the

hydraulic breaker, housing and power cell.
2. Additional devices below may require installing:

Hydraulic control valve (when a spare valve is not
available in control valve bank of a carrier.)
Control pedal or lever.
High pressure supply line to breaker.
Low pressure pipe line for oil return to tank.
Stop valve for shutting off oil lines during attachment
change.
WARNING!
Establish a location fixture as shown to the right, to

safely support the breaker during disassembling.
Disassembling work is very dangerous and requires a
fixture as shown.
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Servicing
a. Prepare a hole and holding pipe for disassembling.
d. If auto-lube kit is installed, detach it first.
Breaker holding pipe

Option
Welding
Steel plate
b. Place the breaker on the fixture securely.

e. Loosen mount bracket bolt.
f. Take out the bracket with hoist and put on the ground
safely.
c. Disassemble hose cover and gas cover.
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Servicing
g. Take out upper damper and power cell holder.
i. Disassemble the shell pad and bottom damper.
h. Pull out the power cell form housing.
WARNING!
Check if the eye bolt is assembled tightly and the chain

or sling is adequate for the weight of power cell.

a. Prepare 3 wooden blocks. The size should be fit
between side mount housing.
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Servicing
b. Put the breaker onto the wooden blocks.
e. Remove the side mount housing with hoist or crane.
c. Disassemble auto-lube.
f. Detach the bottom holder and upper holder from the

power cell.
Option
Upper holder
Bottom holder
d. Disassemble side bolt.
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Servicing
II. Discharge of Nitrogen Gas in the Back Head
d. Open the drain cock and discharge the gas out

completely.
WARNING!
Make sure to discharge nitrogen gas in back head

before disassembly of power cell. If there is any gas in
the hydraulic breaker, it could be very dangerous.
a. Open gas charging valve cap.
Drain cock
III. Power Cell Disassembly
WARNING!
Ensure the power cell is safely supported on the

location fixture during disassembly.
Suitable Eyebolt for Breaker Main Body

b. Assemble gas charge adapter on the port.
Model
0060
0120
0200
0260
0350
0500
0550
0800
0900
1200
1550
1600
1800
2000
2500
3000
3500
4000
7000
c. Connect gas charge kit to the adapter.
Weight
kg
58
60
75
130
190
250
310
406
517
602
725
800
950
1,100
1,280
1,500
1,720
1,960
3,396
lb
120
132
165
287
419
551
683
895
1,140
1,327
1,598
1,764
2,094
2,425
2,822
3,307
3,792
4,321
7,487
Eyebolt
M10
M10
M10
M10
M12
M16
M16
M20
M20
M20
M24
M24
M24
M30
M30
M30
M36
M36
M42
Allowed
weight
kg
150
150
150
150
220
450
450
630
630
630
950
950
950
1,500
1,500
1,500
2,300
2,300
3,400
lb
331
331
331
331
485
992
992
1,389
1,389
1,389
2,094
2,094
2,094
3,307
3,307
3,307
5,071
5,071
7,496
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Servicing
a. Place the power cell securely on the holding fixture.
c. Loosen the nut by hand and remove bolts, plus top &
bottom nuts.

Welding
Steel plate
d. Lift up the back head.
b. Disassemble though bolts.
lb
31
31
31
31
85
92
92
389
389
389
094
094
094
307
307
307
071
071
496
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Servicing
e. Lay back head on wooden blocks as shown and

disassemble o-rings.
h. Disassemble cylinder bush from the piston.
CAUTION: Use wooden or plastic hammer when

disassembling the cylinder bush to prevent damage.
f. Remove holding pin on cylinder.
i. Remove seals from the cylinder bush.
g. Lift up the piston assembly from cylinder.
m. Di
1: Po
be
2: Ins
do
bo
j. Lift up the cylinder.
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Servicing
k. Remove holding pin and O-ring from front head.
n. Disassembly of cylinder

First lay the cylinder on clean and flat shelf.
1. Remove seals.
l. Remove stopper pins and rubber plug for bottom bush

and upper bush.
2. Disassemble plugs.
m. Disassembly of Bushes
1: Position the front head on wooden blocks as shown

below.
2: Insert a round bar into the front head and push it
down with a hydraulic or air press. First take out
bottom bush, followed by the upper bush.
Bottom bush
Upper bush
3. Remove valve cap (eye bolt can be used).
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Servicing
4. Remove valve.
a. Open charging valve cap.
5. Withdraw valve bush with valve-puller.
b. Open needle valve cap.
6. Disassembly of Accumulator
c. Loosen (open) needle valve, you can hear the gas

escaping.
6-1. Discharge Nitrogen Gas in Accumulator.
d. Check gas is completely released by further opening

needle valve.
WARNING!
Make sure to discharge nitrogen gas in the accumulator

before disassembly. If there is any gas in the hydraulic
breaker, it could be very dangerous.
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Servicing
6-2. Loosen accumulator cover bolts and

disassemble accumulator cover.
6-4. Loosen the accumulator body bolt, withdraw

accumulator body and disassemble face-seal.
6-3. Remove diaphragm.
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Servicing
Reassembly
I. Power Cell Assembly
A. Accumulator & Cylinder Assembly
c. Assemble diaphragm (apply grease around the lip of

the diaphragm instead of oil).
CAUTION: Before reassembly of the parts, every part

including accumulator and cylinder must be cleaned and
blown dry.
a. Assembling the face seal.
d. Put accumulator cover and tighten accumulator

cover bolts at specified torque.
b. Tighten accumulator body bolt at specified torque.
e. Charge nitrogen gas (see pages 79 - 82 for

instruction).
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Servicing
f. Assemble valve set after applying oil (apply enough oil)

Two O-rings must be assembled on the valve cap
before assembling the valve set in cylinder.
Model
Cylinder
0060 - 0350
1 2
0500 - 4000
1 2 4
7000
1 2 3 4
*The part no. & shape of seals & O-rings differ from each
model. Therefore, please refer to the Parts List for detail
review.
g. Assemble plugs with O-rings on the cylinder.
4 Buffer ring set

3 Slide seal
2 U-Packing
1 Dust seal
h. Assemble seals apply oil to seals, inside of cylinder
and to grooves.
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Servicing
B. Front Head Assembly
c. Move the front head in assembly hole with hoist or

crane.
a. Assemble upper bush and bottom bush in the front

head.

Welding
CAUTION: Check that bottom bush is orientated so the

groove corresponds with stopper pin. (If orientation is
incorrect, the bush must be disassembled again.)
Steel plate
Bottom bush
Groove
d. Assemble O-ring and holding pin (apply oil on the

seal).
Groove for stopper pin

Upper bush
C. Piston & Cylinder Bush Assembly

a. Replace cylinder onto the front head with hoist or crane
(check the holding pin is assembled on the front).
b. Assemble stop pin and rubber plug in the front head.
WARNING!
Install on holding fixture as shown below to secure

the power cell. Maintenance work is very dangerous
without the specified jig.
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r crane
Servicing
b. Apply oil onto the piston and inside of cylinder before

assembling the piston into the cylinder.
Model
Cylinder Bush
0060 - 0120
1 2 3
0200
1 2 4
0260
1 2 4 5
0350 - 2000
1 2 3
2500 - 7000
1 2 3 5
*The part no. & shape of seals & O-rings differ from each
model. Therefore, please refer to part lists in this manual
for detailed review.
d. Assemble the O-ring and cylinder bush. (Make sure

to locate the cylinder bush fully inside the cylinder
before hammering using clean plastic bar. Then,
assemble holding pin on cylinder.)
c. Apply oil on cylinder bush (inside and outside) and

assemble seals on cylinder bush (apply oil to seals
also before assembly).
O-ring
N2 Gas
Gas seal set
(back up ring set)

3
Step seal
4
U-Packing
5
Slide seal
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Servicing
D. Back Head Assembly
c. Assemble bottom nuts and through bolts, and then

tighten through bolt nut (top nuts) with (power) torque
wrench at specified torque. (see torque chart on page
93)
a. Apply oil onto the O-ring and assemble it into back

head.
CAUTION: Set initial torque at 20 kg.m for model

0060 - 0350, 50 kg.m for model 0500 and over. The
top units should be tightened, when increasing the
torque step by step, in each direction as the arrow
mark on the figure. A
B
C
D.
b. Replace back head on the cylinder.
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n
rque
page
Servicing
Tightening procedure when power torque wrench is unavailable:
Turning (kg.m/N.m/ft.lb)
Model
Through Bolt
(kg.m/N.m/ft.lb)
1 Step
2 Step
Setting
Turning
Setting
Turning
(from 0 flat)
0060
25/245/180
12/122/90
0120
30/294/217
15/147/108
0200
45/441/326
20/196/145
0260
50/490/362
20/196/145
0350
50/490/362
20/196/145
0500
50/490/362
50/490/362
0550
95/931/687
50/490/362
0800
130/1274/940
50/490/362
90/882/651
1/6
0900
160/1568/1258
50/490/362
90/882/651
1/6
1200
240/2352/1738
(270/2646/1953)
50/490/362
90/882/651
0.5/6
1550
270/2646/1953
(310/3038/2242)
50/490/362
90/882/651
0.5/6
1600
270/2646/1953
(310/3038/2242)
50/490/362
90/882/651
0.5/6
1800
330/3234/2387
(380/3724/2749)
50/490/362
150/1470/1085
1.5/6
2000
330/3234/2387
(380/3724/2749)
50/490/362
150/1470/1085
1.5/6
2500
380/3724/2749
(440/4312/3183)
50/490/362
150/1470/1085
1/6
3000
390/3822/2821
(450/4410/3255)
50/490/362
150/1470/1085
1/6
3500
550/5390/3978
(600/5880/4340)
50/490/362
200/1960/1447
1/6
4000
620/6076/4489
(710/6958/5140)
50/490/362
200/1960/1447
1/6
7000
790/7742/5714
Adjust a torque for T/B of 750V is only possible by Power torque wrench.
(Mechanical Power)
*Value in ( ) is applicable to Middle East, India and Mexico. Turning flat (nut degree) on 3rd step and 4th step should be
turned from previous step.
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Servicing
Turning (kg.m/N.m/ft.lb)
3 step
Model
4 step
Setting
Turning
(from previous step)
Setting
Turning
(from previous step)
25/245/180
0060
30/294/217
0120
45/441/326
0200
50/490/362
0260
50/490/362
0350
95/931/687
2.5/6
0500
95/931/687
2.5/6
0550
130/1274/940
2.2/6
0800
160/1568/1258
2.2/6
0900
150/1470/1085
1.5/6
240/2352/1738
1/6
(1.4/6)
1200
150/1470/1085
1.5/6
270/2646/1953
1/6
(1.7/6)
1550
150/1470/1085
1.5/6
270/2646/1953
1/6
(1.7/6)
1600
250/2450/1808
1.5/6
330/3234/2387
0.5/6
(1/6)
1800
250/2450/1808
1.5/6
330/3234/2387
0.5/6
(1/6)
2000
250/2450/1808
1/6
380/3724/2749
1.3/6
(1.9/6)
2500
250/2450/1808
1.5/6
390/3822/2821
1.2/6
(1.8/6)
3000
400/3920/2893
2/6
550/5390/3978
1/6
(1.3/6)
3500
400/3920/2893
2/6
620/6076/4489
1/6
(1.3/6)
4000
Adjust a torque for T/B of 7000 is only possible by Power torque wrench.
(Mechanical Power)
7000
*Value in ( ) is applicable to Middle East, India and Mexico. Turning flat (nut degree) on 3rd step and 4th step should be
turned from previous step.
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Servicing
Procedure of Tightening
1st Step
Tighten the top nuts up to 50 kg.m (490 N.m) with a
torque wrench.
2nd Step
Tighten to the turning number specified on the chart
(see previous page for each model) with ring spanner
and hammer.
* Before tightening to the 2nd step, mark the top nut
and back-head to ensure accurate measurement.
Model
* Tighten nuts with hammer and ring spanner every 1/6

number
turn top nut A 1/6, then B then C
and D in cross pattern.
0060
0120
0200
0260
0350
0500
0550
0800
0900
1200
1550
1600 - 1800
2000
2500 - 3500
4000
7000
* Do not tighten one nut fully, alternate between units

tightening 1/6 of a turn at a time!
Hammer Specification
0260 - 0550: 10 lb
0800 - 1200: 12 lb
1550 - 1800: 16 lb
2000 - 4000: 20 lb
Marking point
Back head
Quantity of Hydraulic Oil (cc)

20 cc
40 cc
50 cc
60 cc
80 cc
150 cc
180 cc
200 cc
220 cc
230 cc
300 cc
340 cc
400 cc
500 cc
700 cc
1,500 cc
e. Assemble the gas charge valve and charge N2 gas,

then assemble gas valve cap. (see page 79 - 82 for N2
gas charging procedure).
D
Top nut
Through bolt
d. Place the assembled power cell horizontally and

re-charge oil into back head.
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Servicing
II. Housing Assembly

d. Assemble the power cell holder and upper damper.
a. Assemble bottom damper, O-rings and shell pad inside

housing.
WARNING!
Install housing assembly securely on holding fixture

as shown below. Maintenance work is very dangerous
without the specified jig.
b. Place the housing onto the assembly hole.
e. Place top bracket onto the housing.
c. Assemble the power cell in the housing with hoist or

crane.
f. Tighten bolts of the top bracket at specified torque.

(see torque chart on page 93).
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Servicing
g. Assemble the hose and gas cover.
b. Place power cell onto the wooden blocks.
h. Assemble the hose cover and auto-lube kit

(optional).
c. Place bottom holder and upper holder onto the
power cell.
Option
Upper holder
Bottom holder
Option
d. Place housing onto the power cell with a hoist or

crane.

a. Prepare 3 wooden blocks.
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Servicing
e. Assemble side bolt and nut, and tighten the nuts at

the specified torque.
f. Assemble the auto-lube kit (optional).

Option
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Servicing
Gas Charging Procedure - Back Head
Open & remove the valve cap.
3
Connect the hose into the charging
adaptor, tighten to hand tightness only.
6
Open the 3-way valve slowly, charge to
(20 kg/cm) then close valve again.
9
Disconnect the adaptor form the
charging valve.
Connect the charging adaptor into the

inlet, tighten to hand tightness only. If
the adaptor is already connected with a
gas hose, the adaptor will not fit onto the
inlet.
Check the bottle valve and 3-way valves

are closed.
Open the bottle valve slowly. The gauge

may be damaged if opened suddenly.
Control the proper pressure (12-16 kg/

cm) opening the drain valve as photo.
* Charge the gas considering the
temperature in the area.
Disconnect the hose from the adapter.
10
Close the cap into the charging valve.
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Servicing
Gas Charging Procedure - Accumulator
Open & remove the valve cap.
3
Connect the charging adaptor to the inlet
(connect the gas hose secondly).
6
Turn the needle valve slowly anti clockwise.
9
Reduce to working pressure (55-60 kg/
cm) using the drain valve as photo.
* Set gas pressure at the ambient
temperature of the working area.
Open & remove the needle cap.
Connect the hose to the charging

adaptor.
Check the bottle valve and 3-way valves

are closed.
Open the bottle valve slowly. The gauge

may be damaged if opened suddenly.
Open the 3-way valve slowly, charge to

(65 kg/cm) then close valve again.
11
10
Close the needle valve.
Disconnect the hose from the adapter.
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alves
Servicing
12
Disconnect the charging adaptor into the
inlet.
13
14
Connect the cap.
Connect the needle cap.
NOTE! During gas charging, the breaker should be laid flat with no contact pressure on the working tools.
Temperature should be as close as possible to that of the working environment.
Check bottle valve has closed then replace the cap on the gas bottle to avoid damage.
Do not expose the gas to the heat sources or extended periods of sun light.
Back Head Gas Charging Pressure

Description
0260 - 0500 for Skid Steer Loader
Back head gas charging pressure
10-12 kg/cm
*CAUTION: When mounting on New Holland Skid Steer loader charge N2 gas at 8-0 kg/cm.
Description
Back head gas charging pressure
0060, 0120, 0260,

0500 - 0900, 3500
0200,
1200 - 4000
0350, 7000
10 - 14 kg/cm
14 - 16 kg/cm
16 - 18 kg/cm
e to
Accumulator Gas Charging Pressure

Description
Accumulator gas charging
pressure
0260 - 0550
0800 - 7000
0260 - 0500 for

Skid Steer Loader
40 - 50 kg/cm
55 - 60 kg/cm
75 kg/cm
Return line:
20 kg/cm
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Servicing
Conversion Table for Charging N2-Gas Pressure to Back Head

0060,
Conversion Table for Charging N2-Gas Pressure to Accumulator
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Servicing
Repair of Parts
3. Piston
Periodically the lower end of piston must be checked for
damage.
When correcting faults on sliding surfaces, surface

finish should be as smooth as possible. Use an oilstone,
emery paper and / or flex hone as required. Avoid
overworking which may cause leaks.
Tool for Correction

Grain Size of Type
Name
of Tool
Oilstone
Emery
paper
Rough
Finish
Finish
Rough &
medium grain
Finish Grain
#100, #160,
#240
#400, #600
Operating
Method
Seizure mark
Check piston for seizure marks and scuffing. If such

marks are on the section, remove by polishing with an
oilstone or sand paper (#1000-1200). Corresponding
marks on the mating part should also be treated in the
same manner.
Polish
perpendicular
to a sliding
direction
1. Inspection
2. Cylinder Bush
When using the buffer grindstone, apply the grinder
correctly to the circumference. If the grinder is led
straight ahead, circularity will be spoiled. Wash the
parts after finishing them.
1. Seals
While seals are still in their original position, check for
scratches and deformation. Do not remove to check.
Even a small scratch will lead to oil leakage.
*Replace hydraulic seals every 500-600 hours of actual
operation as well as just kept over 6 months in storage
(see page 94).
3. Cylinder
Faults on the sliding surface may cause malfunctioning
and oil leakage of the cylinder and in the worst case,
disable the breaker. Correct faults at an early stage,
using an oilstone and emery paper.
2. Control Valve
Inspect valve for signs of seizure or scuffing. If marks
left by the seizure are small, polish by using the fine
oilstone or sand paper (#1000-1200). The
corresponding marks on the valve bush or valve cap
should be removed in the same manner.
If a seizure or scratch is excessive, replace immediately
with a new control valve assembly.
Seizure mark
83
08/10/2014 15:51:39
Servicing
Caution on Using the Buffer Grinder

Kind of Fault
Condition
Remedy
A striped fault running in the

sliding direction of the blow piston.
If burrs stick out above labyrinth grooves,

remove burrs and correct vertical faults
with oil stone and/ or emery paper.
A localized fault that is wider than

the vertical scratch and is caused by
sliding motion.
Finish galling with an oil stone till no step

exists on the outer surface and then finish
with fine emery paper.
Corner of sliding section is chipped.
Finish an edge produced by

chipping smoothly with an oilstone.
Vertical
Scratch
Galling
Chipping
Vermin
A vermin-like fault by cavitations
located at the corner of a sliding part.
A vermin causes galling if left

uncorrected. Remove it with an air grinder
and finish it smoothly with an oilstone.
84
08/10/2014 15:51:40
es,
ts
Servicing
4. Piston
Correct faults at an early stage, using an oilstone and emery paper.
Caution on Using the Buffer Grinder

Kind of Fault
Condition
Remedy
Striped scratches caused by sliding

motion.
Remove burrs on the surface by

polishing in the circumferential direction.
Correct scratches at an early stage as

scratches in this area may develop into
a fatal failure of the cylinder!
Removes burrs sticking above labyrinth grooves, and

finish edges and remedy vertical scratches.
Vertical
Scratch
ep
ish
Scratch in
Labyrinth
Grooves
Reparation
Vertical Scratch
and / or Rust Pit
Taking piston on polishing machine. Remove burrs on

surface by polishing in circumferential direction for
max. 0.05 mm less of normal diameter. If scratches
and / or rust pit still remains, replace piston.
Corner of sliding section is chipped.
der
e.
85
08/10/2014 15:51:40
Servicing
5. Damage on the Impact Surface (bottom of

the piston)
Maintenance Carried out by the Operator

Daily Maintenance
Tighten loose connections.
Grease tool shank and tool bushings.
Observe oil temperature, all lines and connections, as
well as impact efficiency and smoothness of
operation.
Monitor through bolts by checking through the
inspection hole on the bracket.
Damage to the impact head of the piston will cause

faults on the breaker tool. Repair it at an early stage or
replace the damaged piston with a new one.
1. Collapse:
If the impact surface has dents of 2mm or deeper,
replace piston. If damage is under 1mm deep, smooth
the area.
Cylinder
< Very important! >

Weekly Maintenance
Remove retaining pin(s) and check condition.
Remove tool and check tool shank for wear.
Remove burrs from retaining pin groove of the tool.
Check the tool is sufficiently greased.
1mm
Piston
Monthly Maintenance
Check tool bushings for wear.
Check condition of vibration damping mechanism.
Check condition of other wear parts and hoses.
Collapse
2. Chipping / peeling-off
If the impact surface shows localized chipping or
peeling-off, correct the area smoothly to prevent the
progress of the peeling-off.
When Changing Tool or approx. 4 times per year

Maintenance
Check wear to working tool.
Check wear to lower wear bushes.
Check adapter and breaker bracket for cracks.
Check impact face of piston for wear or damage.
Check impact face of working tool for damage.
Check retainer bars for burring.
Check tool for burring.
As required
Replace bent and squashed pipes.
Replace damaged hoses.
Check pressure in piston accumulator.
Check adapter bolts for wear.
3. Chipping of the edge of the impact surface

Requires urgent piston replacement.
86
08/10/2014 15:51:40
Troubleshoot Guide
TROUBLESHOOT GUIDE
Malfunctions
Prerequisites for the normal operation and long life of the hydraulic breaker:
Correct supply rates (Pressure P & flow rate Q) to the hydraulic breaker.
Use of clean hydraulic oil.
Proper operation as per operating & maintenance manuals.
Minor errors may be corrected by customers, but appropriate steps should be taken if their causes cannot be
detected. If the event of malfunction, check the hydraulic system of the excavator thoroughly before repairing the
breaker. Breaker problems can be affected by a hydraulic supply not operating to spec, or problems like plugged fuel
filters or hydraulic filters in the excavator. Connect a flow meter to the excavator to check pump output, relief valve
setting and tube lines to check flow and pressure. The following table lists possible causes and countermeasures;
1. Carrier (Excavator, Backhoe, Skid Loader) and Piping

Conditions
Causes
Countermeasures
Breaker does not work
Insufficient pressure set on relief

valve
Check and set pressure
Excessive pressure set on relief valve
Check and set pressure
Gas pressure is too high
Check the gas pressure
Poor oil cooling of carrier
Have excavator manufacturer check
Premature wear of pump
Clogged piping
Requires flushing
Hose pulsation on the return side
Insufficient oil flow
Check oil flow
Hose pulsation on the high-pressure

line
Gas pressure is too low or high
Check the gas pressure
Emulsification of hydraulic oil
Water contamination of oil
Immediately replace hydraulic oil
Insufficient output of engine
Decrease the gas pressure and

increase RPM
Drop of engine performance
Excessively low temperature of oil
Required warming-up
Breaker damage being caused by

excessive impact power
Rapid increase in oil temperature
Excessive decrease in engine RPM
87
08/10/2014 15:51:40
Troubleshoot Guide
2. Main Body (Breaker)

Conditions
Breaker will not

work
Causes
Countermeasures
Insufficient power (P x Q)
Check power
Insufficient down pressure on tool
Proper instructions
Clogged piping
Check and repair (Flushing)
Seizure of breaker
Repair or replace worn parts
Fillingup of hydraulic oil in back head Replace gas seal and check the piston
Breaker stops working or becomes

erratic following approx. 30-90 min.
operation
Lack of hydraulic oil
Refill oil
Check power
Clogged piping
Check and repair (Flushing)
Check gas pressure
Damaged seals
Replace seals
Fillingup of hydraulic oil in back head Replace gas seal and check the piston
Breaking tool is bent
Apply down force in tool direction
Use of tool as lever to move rocks etc.
Check if any excessive play on arms,

link & pins
Melting of tool point
Long time continuous breaking in one

place
Relocate
Cracking of tool point
Full power operation from the outset
Low speed operation for first 30

minutes
Difficulty in attaching and removing

tool point
Deformation of tool pin
Regular check & grinding needed
Excessively worn urethane (Top

mounting type)
Replace
Loose side bolts (Side mounting type)
Retighten bolts
Lack of grease
Proper instruction
Check power
Proper instructions
Check gas pressure
Gas pressure is too low
Recharge the N2 gas
Proper instructions
Proper instructions
Breakage of tool in bottom bush
Replace tool and check the piston
Tool breakage
Excessive play between bracket and

breaker body
Premature wear of bottom bush
Low number of blow
Weak impact force
88
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Troubleshoot Guide
Oil Leakage
Some oil leakage is acceptable, but in the case of significant leaks call Product Support.
Area of Oil Leakage
Conditions
Causes & Remedies
Between the tool &

bottom bush
A large amount of oil is leaking
Seals are damaged: Replace
Upper part
Oil leaking from hose adapter portion
Loose breaker hoses and adapter: Re-tighten /

replace
Oil leakage from reassembly of valve

or Ro-plug after overhaul
Check that O-ring is damaged: Replace
Oil leakage
Loosed through bolts & nuts: Retighten
Oil leakage (also gas leakage)
Check if the gas seal and O-rings are damaged and

the oil & pistons condition: Replace
Oil leakage
Check that seals of cylinder are damaged: Replace
Between the cylinder &

back head
Between cylinder & front

head
89
08/10/2014 15:51:40
Troubleshoot Guide
Poor Operation of Breaker

Conditions
Does not impact
Irregular blows (possibly

after a period of normal
operation)
Lack of blow
Major Causes
Remedies
Oil temperature is too low
In extreme cold conditions use the machines boom

and dipper services to warm the oil prior to breaker
use.
Main control valve (Excavator) does

not operate properly
Check conditions of M.C.V and power cable
N2 gas pressure is too high in back

head and setting pressure of relief
valve is low
Check gas pressure and relief valve
Poor performance of hydraulic pump

(Excavator)
Contact excavator manufacturer immediately
Oil temperature increased due to lack

of hydraulic oil
Supplement of hydraulic oil
Gas pressure in back head is too high
Check gas pressure
Relief valve is set too low
Check pressure of relief valve
Not enough down pressure

on tool
Apply enough down pressure with arm or boom of

carrier
The clearance between the tool and

front cover are too large
Check the clearance between tool and bottom bush
Wear on top of tool
Disassemble tool to check

and backpressure is too high
Foreign material inside main valve
Disassemble and clean
Seizure of piston & cylinder
Overhaul and check
Low gas pressure in back head
Check gas pressure
Check gas pressure
Not enough down pressure

on tool
Apply enough down pressure with arm and boom
Relief valve is set too low
Check pressure of relief valve
Operating pressure is too high
Check setting pressure or gas pressure
90
08/10/2014 15:51:40
om
ker
of
Troubleshoot Guide
Breaker Tool Failure Caused by Incorrect

Operation / Application
9. Typical fractures caused by excessive bending of the

demolition tool.
1. Bending or breakage of tool. The breaker should only

be used in-line with the tool direction.
2. High wear in normal operation Tool wear is
influenced by the ground conditions.
3. Softening of rod point (Mushrooming). Often caused
by striking the same point for extended periods.
Do not strike at the same point for more than 30
seconds.
4. Chipping of tool tip: Operating breaker at an unstable
setting.
10. Typical fracture caused by levering tool while
buried in the burden.
5. Damage on the impact area, breakage and bending

of tools. This can be caused by abnormal wear of
bush over 8 mm.
Stress
concentration
Point at 90 to
the retainer
pin flats
6. Breakage and abnormal wear in area F can be due to

blank firing.
ush
11. Mushrooming: this is caused by driving the point

into hard dense material for too long a period of
time without penetration. This generates intense
heat, softening the point, thus causing it to
mushroom.
7. Typical high stress fracture, usually caused by using

the machine to pull.
Stress
Concentration
point
Hollow
91
08/10/2014 15:51:41
Troubleshoot Guide
Torque
12. A tool fatigue failure will generally occur

approximately 100mm (4) either side of the chuck
front face.
4 (100mm)
Before starting work, check and tighten any loose bolts

to the specified torque in the manual. The checking
sequence is as follows.
4 (100mm)
ACC Body Bolt
13. The polished semi-circular area in the below picture

is the fatigue area and generally starts from a
damage mark or other stress raiser on the outside
of the tool and spreads inwards.
Through Bolt
Polished
fatigue rings
Stress
concentration
point
Rough
grey area
ACC Cover Bolt
Breakage face
Top Mount Bolt
14. Note: fatigue lines originate from an internal point,

note outer diameter is caused by manufacturing
defects.
ACC Filling Valve Cap

Side Mount Bolt
92
08/10/2014 15:51:41
Troubleshoot Guide
Torque for each Parts

Model
Unit
Through Bolt
Side
mounting
Bolt
Top
Mounting
Bolt
Acc Body
Bolt
Acc
Covers
Bolt
Acc
Filling
Valve Cap
0060
kg.m
N.m
25
245
30
294
45
440
None
None
None
0120
kg.m
N.m
30
294
None
45
440
None
None
None
0200
kg.m
N.m
45
440
None
45
440
None
None
None
0260
kg.m
N.m
50
490
75
735
45
440
45
440
14
137
5
49
0350
kg.m
N.m
50
490
80
784
45
440
45
440
14
137
5
49
0500
kg.m
N.m
95
931
100
980
45
440
45
440
14
137
5
49
0550
kg.m
N.m
95
931
100
980
45
440
45
440
14
137
5
49
0800
kg.m
N.m
130
1,274
None
100
980
60
588
35
343
5
49
0900
kg.m
N.m
160
1,568
150
1,470
100
980
60
588
35
343
5
49
1200
kg.m
N.m
240
2,352
240
2,352
100
980
85
833
35
343
5
49
1550
kg.m
N.m
270
2,646
270
2,646
100
980
110
1,078
35
343
5
49
1600
kg.m
N.m
270
2,646
270
2,646
100
980
110
1,078
50
490
5
49
1800
kg.m
N.m
330
3,234
330
3,234
100
980
110
1,078
50
490
5
49
2000
kg.m
N.m
330
3,234
330
3,234
100
980
110
1,078
65
637
5
49
2500
kg.m
N.m
380
3,724
380
3,724
250
2,450
180
1,764
65
637
5
49
3000
kg.m
N.m
390
3,822
390
3,822
250
2,450
180
1,764
65
637
5
49
3500
kg.m
N.m
550
5,390
550
5,390
250
2,450
180
1,764
65
637
5
49
4000
kg.m
N.m
620
6,076
550
5,390
250
2,450
180
1,764
65
637
5
49
7000
kg.m
N.m
790
7,742
790
7,742
250
2,450
180
1,764
65
637
5
49
93
08/10/2014 15:51:42
Troubleshoot Guide
Wear Parts Replacement Recommendation

1. Listed below are service intervals for replaceable wear parts:
0060 - 1200
Description
Seals
Tool Pin
Bottom Damper
Bottom Bush
Hydraulic Hose*
Diaphragm**
Stopper Pin
Shell Pad
Upper Damper
Through Bolt Set
Upper Bush
600 Hours or
6 Months
1200 Hours or
12 Months
1800 Hours or
18 Months
2400 Hours or
24 Months
Note:
1. Please replace the parts at operating hours or months, whichever comes first.
2. *Check hose condition and replace as required.
3. Hours - Breaker operating hours (excavators operating hours with the breaker installed.)
4. ** Diaphragm not applicable for the MGB0060, MGB0120 and MGB0200.
1550 - 7000
Description
Seals
Tool Pin
Bottom Damper
Bottom Bush
Hydraulic Hose*
Diaphragm
Stopper Pin
Shell Pad
Upper Damper
Through Bolt Set
Upper Bush
500 Hours or
6 Months
1000 Hours or
12 Months
1500 Hours or
18 Months
2000 Hours or
24 Months
Note:
1. Please replace the parts at operating hours or months, whichever comes first.
2. Check hose condition and replace as required.
3. Hours - Breaker operating hours (excavators operating hours with the breaker installed.)
2. Maintaining a stock of spares including tools, tool pins, stopper pins, rubber plugs, through bolts and hoses is
recommended.
3. The above chart is intended as a guideline only and varies according to the carriers condition, the operators skill
and the place of usage.
94
08/10/2014 15:51:42
Notes
or
95
08/10/2014 15:51:42
Contact your Sales Representative

North East: +44 (0)7850 048 762
Southern: +44 (0)7525 237 878
Head Office: +44 (0)1670 707 272
Not all products are available in all markets. Under our policy of continuous improvement, we reserve the right to change
specifications and design without prior notice. The illustrations do not necessarily show the standard version of the breaker.
Part Number: VOMGBOPSERVMAN

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OPERATOR & SERVICE MANUAL

FOR THE HYDRAULIC BREAKER

Operator's & Service Manual.indd 1

Operator's & Service Manual.indd 2

Operators Manual Foreword

OPERATORS MANUAL FOREWORD

This Breaker Operators Manual is intended to serve

The Breaker Operators Manual is written to apply to

Many hours are spent on design and production to

Service and Maintenance

We continually strive to improve our products and

Be sure you are thoroughly familiar with the positions

The symbol above appears at various points in the

Operator's & Service Manual.indd 3

Operators Manual Foreword

Do not operate this breaker and do not carry out any

Spare Parts Order

Operator's & Service Manual.indd 4

Operators Manual Table of Contents

OPERATORS MANUAL TABLE OF CONTENTS

Removal from Packaging

Washing the Attachment

Service Intervals in Special Applications

Recommended Wear Parts Replacement Schedule

SERVICE AND MAINTENANCE

Replacement of the Tool

Cause of Tool Damage

Operator's & Service Manual.indd 5

The breaker is hydraulically powered. It can be

The wooden frames and boxes can be recycled.

No additional pressure accumulators are necessary

Removal from Packaging

Operator's & Service Manual.indd 6

Ensure lifting eyes are fully tightened to the housing

Ensure there are no personnel near the breaker

Lifting eyes on the breaker housing are intended only

Lifting devices must safely carry the working weight of

IMPORTANT! Always remove lifting eyes and replace

Always check the balance of the breaker by lifting it a

IMPORTANT! Always ensure lifting eyes are in good

Operator's & Service Manual.indd 7

Main Structure of the Hydraulic Breaker

Operator's & Service Manual.indd 8

Plates & Decals

Consult manual for proper

Vacate work area while the breaker

A working breaker with

Inject grease into the hole

HIGH PRESSURE requires

Caution - the breaker is HOT

Operator's & Service Manual.indd 9

All mechanical equipment can be hazardous if operated

Always take care and stay alert when working with

Accidents can often be avoided by recognising

Since it is impossible to anticipate every circumstance

Use a hard hat, safety glasses, protective shoes and

Safety is not just a matter of responding to warnings.

Keep other persons away. Do not perform new

Read the following warning messages carefully. They

Read and understand the Operators Manual.

Work sites can be hazardous. Inspect the site before

The machine operator must be thoroughly familiar

Check for potholes, weak ground, hidden rocks, etc.

Breaker Operator's and Services Manual

Breaker Operator's and Services Manual