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MS Operating & Maintenance Manual
MS Operating & Maintenance Manual
2019
Hydraulic
Breaker
1. Introduction .......................................................................................................................................................................................................4
2. Safety Precautions ...........................................................................................................................................................................................4
SPECIFICATION ..................................................................................................................................................................... 5
OPERATION ........................................................................................................................................................................... 11
MAINTENANCE ..................................................................................................................................................................... 17
The aim of this manual is to give you a good understanding of ⧫ Hot hydraulic oil can cause burns. Never use your fingers
the breaker. You will find instructions for safe and effective to check for hydraulic fluid leaks and always keep your face
operation and instructions for regular maintenance activities of away from a possible leak.
the breaker as well.
2. Safety Precautions
Operation
⧫ Operate the breaker for its intended purpose only.
Protective equipment
Maintenance
⧫ Make sure that all gas in the accumulator and back head is
completely relieved before beginning disassembly to avoid
potential accidents or injury.
⧫ Stay clear of the tool when recharging the back head. Gas
pressure may lead unexpected piston movement and
hence the tool movement.
1. Hammer Specifications
SMALL SIZED
Specification Unit MS200 MS220 MS250 MS255 MS300 MS400 MS460
Open Box Open Box Open Box Backhoe Open Box Open Box Open Box
kg 285 325 330 390 410 430 355 470 490 670 665 830 890
Working Weight
(lb) (630) (720) (730) (860) (905) (950) (785) (1040) (1080) (1480) (1465) (1830) (1965)
Impact Rate bpm 500 - 1000 500 - 1200 520 - 1000 500 - 900 350 - 700 350 - 650
Operating bar 110 -130 120 - 140
Pressure (psi) (1595 - 1885) (1740 - 2030)
Relief bar 160 - 180
Pressure (psi) (2320 - 2610)
L/min 40 - 50 40 - 90 60 - 85 70 - 90 70 - 100
Oil Flow
(gal/min) (10 - 13) (10 - 24) (15 - 23) (18 - 24) (18 - 26)
bar 10
Back Pressure
(psi) (145)
Accumulator bar 60 40 60
Pressure (psi) (870) (580) (870)
Pressure mm 12 19
Line Size [IN] (inch) (1/2) (3/4)
Return mm 12 19
Line Size [OUT] (inch) (1/2) (3/4)
ton 2-6 3-7 3-8 5 - 10 7 - 12 10 - 16
Carrier Weight
(lb) (4400 - 13200) (6600 - 15400) (6600 - 17600) (11000 - 22000) (15400 - 26400) (22000 - 35200)
MID-SIZED AT SERIES
Specification Unit MS520 MS550 MS600 MS700 MS30AT MS 35AT MS 45AT MS55AT MS 75AT
Box Box Box Box BOX Box Box Box Box
Working kg 1200 1500 1734 2250 2440 2950 3750 5500 7500
Weight (lb) (2645) (3306) (3822) (4960) (5380) (6504) (8267) (12125) (16535)
Back bar 10
Pressure (psi) (145)
Accumulator bar 40 50
Pressure (psi) (580) (725)
Pressure mm 19 25 32 24
Line Size [IN] (inch) (3/4) (1) (1-1/4) (1-1/2)
Pressure
mm 25 32 38 50
Line Size
(inch) (1) (1-1/4) (1-1/2) (2)
[OUT]
14 - 18 18 - 25 22 - 28 25 - 32 28 - 32 30 - 45 40 - 55 50 - 75 70 - 100
Carrier ton
(30800 - (39600 - (48500 - (55100 - (61700 - (66100 - (88100 - (110200 - (154300 -
Weight (lb)
39600) 55100) 61700) 70500) 70500) 99200) 121200) 165300) 220400)
5
SPECIFICATION
2. Main Dimensions
A B C D E F G
Backhoe
mm mm mm mm mm mm mm
MS255 295 1146 1635.1 250 615 75 -
A B C D E F G
Open
mm mm mm mm mm mm mm
MS200 360 838 1260 284 408 240 63
MS220 360 904.5 1343 284 420 280 70
MS250 380 973 1460 302 440 300 75
MS300 380 1049 1549 315 480 320 85
MS400 380 1186 1756 324 480 350 95
MS460 500 1290 1867 386 500 380 100
A B C D E F G
Box
mm mm mm mm mm mm mm
MS200 400 923.5 1296 220 400 250 63
MS220 400 962.5 1351 230 400 260 70
MS250 450 1064 1501 260 450 290 75
MS300 450 1132 1585 270 450 305 85
MS400 500 1274 1790 304 500 339 95
MS460 500 1388 1908 340 500 380 100
MS520 510 1603 2280 360 570 400 110
MS550 510 1835 2473 410 570 460 120
MS600 570 1853 2506 430 600 490 130
MS700 570 2085 2730 460 600 520 140
MS30AT 630 2186 2880 520 630 470 150
MS35AT 730 2371 3080 482 730 565 165
MS45AT 820 2531 3361 540 730 620 175
MS55AT 860 2688 3533 620 860 700 180
MS75AT 1000 3090 3886 730 1000 800 205
6
SPECIFICATION
3. Bolt Patterns
A B C D E F G H I
Model Housing
mm mm mm mm mm mm mm mm mm
open 408 360 100 160 100 85 145 85 21
MS200
box 400 400 100 150 100 100 150 100 21
open 420 360 90 160 90 66 170 66 21
MS220
box 400 400 100 150 100 100 150 100 21
open 440 680 95 160 95 85 170 85 21
MS250
box 450 450 120 160 120 120 160 120 21
MS255 backhoe - - - - - - - - -
open 480 380 90 210 90 85 170 85 21
MS300
box 450 450 120 160 120 120 160 120 21
open 480 380 90 210 90 85 170 85 21
MS400
box 500 500 135 180 138 135 180 135 21
open 500 500 135 180 135 135 180 135 21
MS460
box 500 500 135 180 135 135 180 135 21
A B C D E F G H I J
Model Housing
mm mm mm mm mm mm mm mm mm mm
MS520 box 510 570 105 120 120 105 105 300 105 27
MS550 box 510 570 105 120 120 105 105 300 105 27
MS600 box 570 600 125 130 130 125 102 316 102 27
MS700 box 570 600 125 130 130 125 102 316 102 27
MS30AT box 630 630 135 140 140 135 112 326 112 33
MS35AT box 730 730 160 165 165 160 130 390 130 39
MS45AT box 730 730 160 165 165 160 130 390 130 39
MS55AT box 860 860 190 190 190 190 170 420 170 39
MS75AT box 1000 1000 215 215 215 215 185 490 185 39
7
SPECIFICATION
4. Carrier Weight
Breaker CARRIER WEIGHT (ton)
Model 0 10 20 30 40 50 60
00
MS200 2-6
MS220 3-7
MS250 3-8
MS255 3-8
MS300 5- 10
MS400 7- 12
MS460 10 - 16
MS520 14 - 18
MS550 18 - 25
MS600 22 - 28
MS700 25 - 32
MS30AT 28 - 32
Carrier Weight
Breaker
ton
Model
35 45 55 65 75 85 95
00
MS35AT 30 - 45
MS45AT 40 - 60
MS55AT 50 - 75
MS75AT 70 - 100
8
SPECIFICATION
5. Tool Specifications
9
SPECIFICATION
6. Structure
SIDE ROD
VALVE HOUSING
Hydraulic ports and operation control valve are built into the
valve housing.
CYLINDER
ACCUMULATOR
PISTON
FRONTHEAD
Front head holds the tool via thrust ring and built-in upper
bushing.
TOOL
10
OPERATION
⧫ Tool
⧫ Piston
⧫ Cylinder
⧫ Front head
11
OPERATION
The correct choice of the most suitable tool is crucial not only
for increasing hydraulic breaker productivity but also for the life
of the tool itself
Installation
1. Before connecting the hammer, make sure to carry out
flushing first to prevent hammer from being contaminated
external particles from hoses and etc.
12
OPERATION
5. Operating Precautions
⧫ Keep the cabin windows and doors closed during operation ⧫ When the object starts to break, stop the hammer
immediately. Do not allow the hammer to fall down and
make idle strokes. Frequent idle strokes would lead
deteriorating effect on the hammer components.
13
OPERATION
7. Hydraulic Circuit
When the oil is too thick, the following problems may occur:
⧫ Difficult start up
⧫ Stiff operation
⧫ Sticky valves
⧫ Leakage
14
OPERATION
Recommended is a lithium soap base NLGI grade 2 grease
9. Oil Filter with Molybdenum Disulfide or other surface protecting additives
and drop point of 260°C.
The purpose of the oil filter is to remove impurities from the
hydraulic oil. Impurities normally enter the carrier hydraulic
system in case of repairing components, installing the hammer
Greasing interval
on the carrier. ⧫ Tool shank must be well lubricated before installing tool.
⧫ The oil filter material must be man-made fiber cloth or very ⧫ This should be done every 2 hours of operation.
fine gauge metallic mesh to withstand pressure fluctuations. ⧫ If the grease schedule cannot be controlled, then grease the
⧫ The oil filter must have a nominal flow capacity of at least hammer more often than required, for example, once every
twice the hammer's max. flow hour. It is far cheaper than replacing prematurely worn out
tool or tool bushings.
⧫ In general, oil companies guarantee new oils to have a
particle count of 40 microns maximum. Filter the oil when ⧫ Insufficient greasing or use of improper grease may cause
filling the tank. breakage of tool or abnormal wear of tool or tool bushings.
⧫ Reduced working life of the pumps and other components When greasing, the hammer must be standing upright resting
on the tool to ensure that the grease penetrates downwards
⧫ Cavitation
between the tool and the tool bushing. This prevents grease
⧫ Oil leakage from entering piston impact area and ensures proper
distribution of grease between the tool and bushings.
⧫ Oil overheating
⧫ Piston seizing up
Automatic lubrication
⧫ Spools binding Lubrication of the hammer can be made automatically by
equipping the carrier with a lubrication pump. The tool grease is
10. Oil Cooler supplied from the pump into the hammer by hose. This is
The correct place to connect the hammer return line is between recommended for longer service life of wear parts.
the oil cooler and the main filters. The hammer return line
should not be connected before the oil cooler. Routing the
hammer flow through the cooler, might damage either the
cooler, due to pulsating flow, or the hammer, due to increased
back pressure.
11. Lubrication
Proper hammer maintenance requires a sufficient supply of the
correct grease to the tool.
15
OPERATION
In ASO Off Mode, the breaker starts without load applied to the
tool, thus simplifying handling by saving time to position the
breaker. This provides great productivity through increased
efficiency of hammer operation.
② Remove ASO PIN (Keep the ASO PIN well for reuse).
16
MAINTENANCE
Greasing 〇
Membrane Breakage 〇
Housing Abrasion 〇
Seal Leakage 〇
17
MAINTENANCE
2. General Precautions
Maintenance instructions should be followed to ensure the ⧫ Check if the housing joint bolts and the top cover bolts are
breaker operating in best condition. Check every components loosened. Replace or retighten if necessary.
of the machine before and after operating the breaker and ⧫ Check the gas pressure in the back head. Recharge if
repair or replace the related items if necessary for maximum necessary.
durability.
⧫ Check the hydraulic oil condition. Replace or refill if
necessary.
Clean the machine before inspection
Breaker housing should be cleaned for removing dirt before Every 100 hours or at least once a month
inspection to ensure proper detection of damage of the
⧫ Check all the connection of hydraulic pipe line and in/out
breaker.
hoses.
Keep away from the heat ⧫ Check the operating pressure and the oil flow setting.
Adjust if necessary.
Excavator, breaker body, hydraulic oil still have high level of
temperature after certain operation. Due to the reason, do not ⧫ Check the relief pressure of the hydraulic system from the
touch any parts which has high temperature and wait until they main carrier.
are cooled down, otherwise it may cause serious injury.
Every 600 hours of at least once a 6 month
Release pressure in the hydraulic system ⧫ Make a regular exterior inspection (crack, loosening, oil
leakage, etc.) of the breaker and the main carrier.
Before disassembling hydraulic parts (e.g. hydraulic hose, plug,
adjust bolt), make sure that stop valves on both hydraulic lines ⧫ Check every part of the power cell, the housing, and the
are fully closed and wait until the pressure in the hydraulic bracket.
system of the machine are lowered to prevent hydraulic oil
⧫ Change all the seals including the membrane in the
from popping out.
accumulator.
Keep record inspection history ⧫ Check if the side rod bolts have cracks on the threads.
Inspect the machine regularly and record the inspection result ⧫ Check all the hydraulic connections.
for future maintenance. ⧫ Replace and inspect the hydraulic oil filters of the main
carrier.
3. Periodical Inspection & Schedule
All the times below refer to the machine hours measured while
4. Storage
the breaker is being installed.
Short term storage
Every 2 hours For short term storage between works, place the hammer
⧫ Grease the tool and the tool bushing horizontal on wooden blocks. Make sure that the tool is
lubricated and the hydraulic hoses are securely capped. Cover
the hammer with a waterproof tarp.
Every 10 hours or at least once a day
⧫ Check the wear conditions of the tool and the tool pin. Long term storage
Grind off if necessary.
Check the followings for safe long term storage of the hammer
⧫ Check if the tool has sufficient greasing. Grease if to prevent rust and to make the hammer ready to be used.
necessary.
⧫ Hammer must be stored in upright position.
⧫ Check if the housing bolts and the top bracket bolts are
loosened. Retighten if necessary. ⧫ Discharge the gas pressure on the back head.
⧫ Remove the tool and push the piston all the way in.
Every 50 hours or at least once a week
⧫ Grease the exposed front end of the piston.
⧫ Remove the tool, the tool bushing, and the bushing pin,
⧫ Plug the hydraulic hoses.
and check the wear conditions thereof.
⧫ Cover the hammer with a waterproof tarp
⧫ Check the hydraulic hoses. Replace if damaged. Do not let
dirt get into the hammer or the hoses.
18
MAINTENANCE
6. Fill the groove between the side rods and the front head with
silicon compound.
19
MAINTENANCE
① Tool ②Tool Bushing ③ Upper Bushing ④ Thrust Ring ⑤ Tool ⑥ Tool Pin
Model New Reject New Reject New Reject New Reject New Reject New Reject New Reject
E
(A) (B) (A) (B) (A) (B) (A) (B) (A) (B) (A) (B) (C) (D)
MS200 63 61 63 65 - - - - 370 250 35 33 - - -
MS220 70 68 70.5 67 - - - - 388 250 40 38 - - -
MS250 75 73 75 77 75 77 6 11 437 250 40 38 - - -
MS255 75 73 75 77 75 77 6 11 437 250 40 38 - - -
MS300 85 83 85 87 85 87 8 13 453 250 45 42 - - -
MS400 95 93 95 97 95 97 9 14 516 350 50 48 - -
MS460 100 98 100 102 100 102 9.5 14.5 520 350 40 37 80 77 1.5
MS520 110 108 110 112 110 112 10 15 673 450 40 37 80 77 1.5
MS550 120 118 120 122 120 122 12.5 17.5 638 450 45 42 85 82 1.5
MS600 130 128 130 132 130 132 11.5 16.5 655 450 45 42 100 97 1.5
MS700 140 138 140 142 140 142 12.5 17.5 650 450 50 47 125 123 1.5
MS30AT 150 148 150 152.5 150 152 - - 695 500 50 47 125 123 1.5
MS35AT 165 162.5 165 167.5 165 167 - - 709 500 50 47 130 127 1.5
MS45AT 175 172.5 175 177.5 175 177 - - 830 550 50 47 130 127 1.5
MS55AT 180 178.5 180 182.5 180 182 - - 943 600 50 47 130 127 1.5
MS75AT 205 200 205 210 205 207 943 600 65 62 155 152 1.5
20
MAINTENANCE
ITEM UNIT MS550 MS600 MS700 MS30AT MS35AT MS45AT MS55AT MS75AT
Acc. Gas Pressure bar 40 40 40 40 40 40 40 50
Acc. Gas Bolt 30 30 30 30 30 30 30 30
Acc. Cover Bolt 650 700 700 700 1250 1250 1250 1250
Acc. Bottom Bolt 450 450 450 450 450 550 550 550
500 500 700 700 700 700 700 700
Side rod N.m
100˚ 120˚ 120˚ 120˚ 120˚ 120˚ 120˚ 120˚
Housing joint bolt - - - - - - - -
Top Cover bolt 650 650 650 1350 2300 2300 2300 2300
Oper. V/V Cover Bolt 100 100 100 100 200 200 200 200
Sleeve cover Bolt 150 200 200 200 500 500 500 500
21
DISASSEMBLING AND ASSEMBLING
Disassembling
1. Remove the tool and set the breaker to vertical position on the
floor.
3. Install the washer and cap nut the housing joint bolts Assembling
4. Connect the mounting bracket by tightening the mounting 1. Clean and dry parts carefully.
bracket bolts. 2. Set the accumulator bottom K on the assembly stand and install
the guide pin J.
5. Remove the plugs from the hoses and then connect the hoses
and the breaker inlet and outlet 3. Fit a new membrane I in place. Apply silicon
grease on the gas side of the membrane as
6. Connect pressure and return lines
well as on the accumulator cover H.
6. Install the bottom bolt G. Tighten the bottom bolt G with torque
wrench to the torque 500N·m.
1. Install the seal F into the grove in the bottom of the accumulator.
Use grease to prevent the seal from failing out during mounting.
2. Assembling and Installing accumulator set 2. Apply MoS2 spray on the contact surfaces of accumulator M,
housing L.
1. Remove the hammer from housing.
3. Lift the accumulator into place on the valve housing.
2. Set the hammer accumulator and lifting the hammer with a
4. Apply thread grease to the thread area and the accumulator cover
lifting ring A.
bolt E.
3. Remove the lifting ring A and the accumulator cap B.
5. Tighten the bolts with a torque wrench to the valve shown in the
4. Carefully open the accumulator gas bolt C to allow the nitrogen torque specifications.
gas to flow out.
5. Remove the accumulator gas bolt C and usit ring D when all
the pressure is released from the accumulator.
22
DISASSEMBLING AND ASSEMBLING
Disassembling
Installation
1. Check the parts carefully. If necessary use fine emery cloth or
grinding agent to remove any scratch or burrs. Clean and oil
grease parts.
2. Install new O-rings G on the covers Band C.
3. Install new O-rings H (6pcs) in the sleeve I.
4. Fasten the extractor on the valve housing side marked with X.
Install the sleeve so that X on its end comes to the same side
1. Loose operating cover bolt and J, I by using 8mm hex. Wrench. 6. Install covers B (cover marked with X comes to the same side
with valve housing X)
2. Remove G, H.
7. Grease tab area and cover bolts A. Install locking washers J and
3. After disassembling A, C firstly, later on, disassemble B, D, cover bolts A.
E and F as one by one. 8. Tighten the bolts with a torque wrench. Refer to the torque
specifications.
Installation 9. When assembling and disassembling the main spool, sleeve the
1. Put shim plate which need to adjust oil pressure into the extractor K must be used.
center hole inside operation valve cover.
23
24
DISASSEMBLING AND ASSEMBLING
25
DISASSEMBLING AND ASSEMBLING
4. Remove spring guide B, spring D, spool E, O-ring F and G 2. Remove the tool pin B.
3. Remove the tool C and tool bushing D. Check the tool and
5. Tighten the bolts A with a torque wrench. Refer to the 1. Push the spring pin A as far as it will go.
2. Remove the tool pin B.
torque specifications
3. Remove the tool C.
4. Remove the tool bushing pin D.
5. Remove the tool bushing E. Check the tool and tool bushing
for wear.
[MS460-75AT]
1. Remove the bushing pin A.
2. Remove the tool pin B.
3. Remove the tool C.
4. Remove the tool bushing pin D.
5. Remove the tool bushing E. Check the tool and tool
bushing for wear.
26
Installation
1. Clean all parts.
2. Apply MoS2 spray to the contact surfaces of the tool holder
bushing and fronthead.
[MS200-220]
1. Install the tool bushing and tool.
2. Install the tool pin.
3. Install the spring pin.
[MS250-400]
1. Install the tool bushing.
2. Install the tool bushing pin.
3. Install the tool.
4. Push the spring pin as far as it will go.
5. Install the tool pin
[MS460-75AT]
1. Install the tool bushing.
2. Install the tool bushing pin.
3. Install the tool.
4. Install the tool pin.
5. Install the bushing pin.
27
TROUBLE SHOOTING GUIDE
⧫ Leakage from return line in carrier hydraulic circuit ▶The hammer must be serviced in an authorized service
shop.
▶Check the installation. Check the pump and the other
hydraulic components.
4. Impact rate slows down
⧫ Pressure and return hoses installed backwards
⧫ Oiloverheated (over 176°F /80°C)
▶Change the pressure and return hoses.
▶ Check for a fault in the oil cooling system or an internal
⧫ Failure in hammer valve operation leakage in the hammer. Check the hydraulic circuit of the
carrier. Check the relief valve operation in the carrier.
▶The hammer must be serviced in an authorized service
Check the line size. Assemble an extra oil cooler.
shop.
⧫ Relief valve in hydraulic circuit opens at a low pressure.
⧫ Piston failure
Hammer operating pressure is not reached
▶The hammer must be serviced in an authorized service
▶ Check the installation. Check the relief valve operation.
shop.
Adjust the relief valve in hydraulic circuit. Measure the high
pressure in the hammer inlet line.
2. The hammer operates irregularly but the
⧫ Leakage from return line in carrier hydraulic circuit
blow has full power ▶ Check the installation. Check the pump and the other
⧫ Relief valve in hydraulic circuit opens at a low pressure. hydraulic components.
Hammer operating pressure is not reached ⧫ Pressure loss in the accumulator
▶Check the installation. Check the relief valve operation. ▶ The hammer must be serviced in an authorized service
Adjust the relief valve in hydraulic circuit. Measure the high shop.
pressure in the hammer inlet line.
⧫ Failure un hammer valve operation
⧫ Failure in hammer valve operation
▶ The hammer must be serviced in an authorized service
▶The hammer must be serviced in an authorized service shop.
shop.
⧫ Hydraulic viscosity is too low
⧫ Not enough feed force from the carrier
▶ Check hydraulic oil
▶Refer to correct working methods
28
TROUBLE SHOOTING GUIDE
5. Oil overheats
⧫ Relief valve in hydraulic circuit opens at a low pressure.
Hammer operating pressure is not reached
29
ACCESSORY TOOLS
30
WARRANTY REPORT
Document No.
(Leave this area blank - to be filled out by the manufacturer)
1. PRODUCT INFO.
Serial number Installation date
Note: If the installation card has not been submitted previously, it shall be sent along with this warranty
report.
2. FAILURE INFO.
Failure date
Symptom / Concern
Repair / Action taken
Status
Image Description
3. PART REQUIRED
No. Part number Part name Q'ty
4. DEALER INFO.
REQUESTED BY (Corporate name)
REPORTING DATE
31
91, Namdong-daero, Namdong-gu, Incheon, Korea
www.msbcom.co.kr