GESR0848-03

May 2019

Service Manual
B35 Hydraulic Breakers

MXE 1 - UP

1
FOREWORD

WARNING
In order for CAT to conduct optimum performance on your jobsite, understand all the detail
information of this manual. You must observe all relevant laws and regulation before and after
operation. Otherwise you and others can be seriously injured.

This manual instructs you on safe operation and maintenance of your CAT hammer.

u Study this manual before installing, operating or maintaining this equipment.

u This hammer is a powerful tool. Used without proper care, it can cause damage of product
or serious injury.

u Use it properly and use it well. Pay particular attention to all safety messages.

u To use the hammer correctly, you must also be competent operator (assistant) of the carrier
machine.

u Do not use or install the hammer if you cannot use the carrier machine.

u Do not rush the job of learning. Take your time and most important, take it safely.

u If there is anything you do not understand, ask your CAT dealer. He will be pleased to advise
you.

u It may cause serious injury and death when operators do not follow operational manuals and
warnings.

u Operators should not overlook the guidelines of which they don't understand and should fully
understand all safety guidelines and warnings before operating machines.

u Operation manual and warning symbols in the manual are very important for safety.

u Operators should maintain those manuals in a good condition and replace them if damaged.

u It is strongly recommended that genuine spare parts supplied by CAT must be used at all
times.

u Use the right tools to install, remove, repair or replace the hammer and spare parts.

u Although this manual does not cover all possible cases, personnel in work site must be alert
to potential hazards himself.

2
TABLE OF CONTENTS

SERVICE MANUAL

u FOREWORD ........................................................................................................................................................................................ 2

u TABLE OF CONTENTS ....................................................................................................................................................................... 3

u SAFETY ALERT SYMBOLS ................................................................................................................................................................. 5

u INSTRUCTION OF HYDRAULIC BREAKER .......................................................................................................................................... 6

u PRODUCT SERIAL NO. ...................................................................................................................................................................... 7

u PRODUCT WARNING LABEL .............................................................................................................................................................. 8

SAFETY INFORMATION

1. BASIC INFORMATION ........................................................................................................................................................................... 11

2. PRECAUTION BEFORE OPERATION ...................................................................................................................................................... 13

3. PRECAUTION DURING OPERATION...................................................................................................................................................... 15

4. PRECAUTION AFTER OPERATION ........................................................................................................................................................ 18

OPERATION

1. HAMMER INFORMATION ...................................................................................................................................................................... 20

1-1 PART NAME & STRUCTURE ......................................................................................................................................................... 20

1-2 GENERAL SPECIFICATION ............................................................................................................................................................ 21
1-3 ADVANTAGE OF "B-SERIES" BREAKER.......................................................................................................................................... 22
1-4 FUNCTION & FEATURES............................................................................................................................................................... 23
1-5 EXTERNAL DIMENSIONS OF EACH MODEL .................................................................................................................................. 28

2. INSTALLATION & REMOVAL OF BREAKER.......................................................................................................................................... 29

2-1 KEY POINTS FOR SELECTING HAMMER ....................................................................................................................................... 29

2-2 HYDRAULIC CIRCUIT .................................................................................................................................................................... 30
2-3 INSTALLATION.............................................................................................................................................................................. 31
1) DIMENSION OF TOP PLATE......................................................................................................................................................... 31
2) TOP BRACKET ASSEMBLY ........................................................................................................................................................... 32
3) PIPE FLUSHING ........................................................................................................................................................................... 33
4) INSTALLATION OF BREAKER ....................................................................................................................................................... 34
5) CONNECTING IN/OUT LINE HOSE ................................................................................................................................................ 36
6) CONNECTION PORTS OF THE HAMMER ...................................................................................................................................... 37
2-4 REMOVAL OF BREAKER ............................................................................................................................................................... 38
2-5. CHECK POINTS WHEN SETTING HYDRAULIC LINE TO BREAKER ................................................................................................ 40
2-6. OPERATION PROCEDURE ............................................................................................................................................................ 41
1) PREPARATION OF SAFE OPERATION ........................................................................................................................................... 41
2) PRECAUTION OF BEFORE OPERATION ........................................................................................................................................ 42

2-7. CORRECT OPERATION ................................................................................................................................................................. 43

3. STORAGE.............................................................................................................................................................................................. 49

3-1. SHORT TERM STORAGE ........................................................................................................................................................... 49

3-2. LONG TERM STORAGE ............................................................................................................................................................. 50
3-3. OPERATION AFTER LONG TERM STORAGE .............................................................................................................................. 51

4. TROUBLE SHOOTING............................................................................................................................................................................ 52

5. OPERATING PRINCIPLE........................................................................................................................................................................ 54

6. SPECIAL APPLICATION ........................................................................................................................................................................ 58

6-1. UNDERWATER JOB ................................................................................................................................................................... 58

3
TABLE OF CONTENTS

MAINTENANCE

1. GENERAL PRECAUTION ........................................................................................................................................................................ 65

2. PERIODICAL INSPECTION & SCHEDULE .............................................................................................................................................. 67

2-1. EVERY 2 HOURS INSPECTION.................................................................................................................................................. 67

2-2. DAILY INSPECTION................................................................................................................................................................... 67
2-3. MONTHLY INSPECTION ............................................................................................................................................................ 68
2-4. YEARLY INSPECTION ................................................................................................................................................................ 69

3. HYDRAULIC OIL ................................................................................................................................................................................... 70

4. LUBRICATION ....................................................................................................................................................................................... 73

5. CHARGING GAS.................................................................................................................................................................................... 75

5-1. BACK HEAD .............................................................................................................................................................................. 75

5-2. ACCUMULATOR ........................................................................................................................................................................ 78

6. WEAR LIMIT FOR CONSUMABLES....................................................................................................................................................... 84

7. TORQUE................................................................................................................................................................................................ 87

8. REPAIR & REPLACEMENT.................................................................................................................................................................... 91

8-1. HOUSING .................................................................................................................................................................................. 91

8-2. SIDE ROD ................................................................................................................................................................................. 92
8-3. SEAL REPLACEMENT ................................................................................................................................................................ 94
8-4. PISTON..................................................................................................................................................................................... 96
8-5. TOOL & TOOL BUSHING .......................................................................................................................................................... 97

9. DISASSEMBLE THE HAMMER POWERCELL ....................................................................................................................................... 100

9-1. ASSEMBLY PROCEDURE OF ACCUMULATOR ......................................................................................................................... 105

10. ADJUSTMENT ..................................................................................................................................................................................... 108

10-1. CYLINDER ADJUSTER ........................................................................................................................................................... 108

10-2. VALVE ADJUSTER ................................................................................................................................................................ 109

TOOL FAILURE ANALYSIS

1. GUIDELINE FOR VARIOUS TOOL FAILURES ...................................................................................................................................... 112

1-1. TOOL FAILURE ACCEPTED UNDER GOODWILL ....................................................................................................................... 114

1-2. TOOL FAILURE REJECTED UNDER WARRANTY....................................................................................................................... 115

WARRANTY

4
SAFETY ALERT SYMBOLS

1. SAFETY INFORMATION
The manual is intended to provide safety information necessary for safe and efficient use of “B-
series” hydraulic breaker. "DANGER", "WARNING", "CAUTION" symbols may appear in the text of
this manual. It is used to alert the operator of an action that can cause serious injury or death to
him/her or other personnel.
In general, most safety accidents are caused by carelessness, or negligence of safety
instructions or equipment maintenance. Those accidents can enough be prevented by
understanding safety information and potential hazards.
The safety messages can not cover all the possibilities that could cause injury, death or damage
to the product. Nevertheless, it is the operator's duty to obey safety rules and precaution.
Safety symbols are provided in this manual and on the machine. Serious injury or death could
occur, if person in site ignores and disregards the warnings.
Always read the information in this manual before operation the hammer.

Safety Alert Symbol

CHECK that all safety decals attached to the hammer, and symbols in this manual.
Failure to do so can result in personnel injury of damage to the machine.

Safety alert symbols are as follows:

DANGER
DANGER indicates an imminently hazardous situation which, if not heeded, will result in serious
injury or death.

WARNING
WARNING indicates a potentially hazardous situation which, if not heeded, could result in serious
injury or death.

CAUTION
CAUTION indicates a potentially hazardous situation which, if not heeded, could result in serious
injury or death.

NOTICE
NOTICE indicates general safety measure and information regarding product property and
damage.

NOTE
Special technical notice or other notices for preserving standards are necessary with performing
the work.

5
INTRODUCTION OF HYDRAULIC BREAKER

DEFINITION & APPLICATION

HYDRAULIC BREAKER is a powerful percussion hammer for demolishing, breaking concrete

structures of rocks.

HYDRAULIC BREAKER, much larger than portable ones, is powered by hydraulic system from the
excavator, and fitted to mechanical excavators or backhoes.

HYDRAULIC BREAKER is widely used for

- ROAD WORK
- QUARRYING
- GENERAL DEMOLITION
- CONSTRUCTION GROUND WORK
- MINING WORK

6
PRODUCT SERIAL NO.

The serial number is stamped on the back head of the breaker main body.
It is important to make correct reference to the serial number of the machine when asking for
repairs or ordering spare parts. Identification of the serial number is the onl
onlyy proper means of
maintaining and identifying parts for a specific product.

< B35 >

-7-
PRODUCT WARNING LABEL

HAMMER LABEL

1. Safety Decal on gas charging in back head

P/N : 372
372-5013

2. Safety Decal on gas charging in accumulator.

P/N : 372
372-5014

3. Greasing Decal

The greasing point on the hammer has been

marked with the following sticker.

< B35 >

P/N : 372
372-5015

8
PRODUCT WARNING LABEL (OPEN TYPE)

HOUSING LABEL

P/N : 375-8530

P/N : 370-3885

< B35 >

< B35 >

P/N : 372-5016

9
 SAFETY
INFORMATION

WARNING

Be sure to fully understand the precaution of “SAFETY INFORMATION”.

Improper action by ignorance or negligence the guidelines will result
in serious injury or death.

10
SAFETY INFORMATION

1. BASIC INFORMATION

UNDERSTANDING
DERSTANDING OF OPERATION MANUAL

Not observing operational guideli

guidelines may cause serious injury or death in extreme case. Operator
should follow operating guidelines of excavator & hammer
hammer, and operate machines after fully
understand those guidelines. Operation manual and guidelines should always be attached to
excavator.

OPERATION MANUAL & WARNING

It may cause serious injury and death when operators do not follow operation manuals and
warnings. Operators should not overlook the guidelines of which they don't understand and
should fully understand all safety guidelines and warnings before operating machines.
Operation manuals and warnings ar
aree very important for safety. Operator should maintain those
manuals in a good condition and replace them if damaged.

OPERATION MANUAL & WARNING

ING OBSERVATION

edness, lack of
Operators should not operate machine if not in operative condition due to tiredness,
sleep and medication. Operators should take regular medical check up to maintain good health
condition.

11
SAFETY INFORMATION

WEARING SAFETY GEAR

Operator should
ould wear safety hat and shoes.
If necessary, operators should wear safety goggles, mask, and ear loaf and safety shoes

PREVENTION OF FIRE AND ACCIDENT

Operators should keep emergency aid kit and fire extinguisher near
near-by
by to use them in an
emergency.
Operators should learn how to handle fire extinguisher and keep emergency contact numbers.

OPERATIONAL WORK SITE RULES

Operators should follow safety rules, guidelines, and procedure of the work site to maintain safe
work environment.

12
SAFETY INFORMATION

2. PRECAUTION BEFORE OPERATION

HEAD GUARD ATTACHMENT TO EXCAVATOR

Operators should install guard or tops to the excavator cabin in order to prevent potential risk
caused by the scattered or fallen rocks from the breaker work site.

WINDOW SAFETY GUARD INSTRUCTION

Window safety guard should be always be used with the hydraulic hammer.

CHECK WORK SITE CONDITION

Operators should check the geological or soil condition before the machine operation to detect
any possible accident.

EQUIPMENT CHECK BEFORE MACHINE OPERATION

Before starting engine, operator should check the machine condition and replace any breaking
part if any problem found.

The following parts should be checked:

- Leakage of the hydraulic system or other functioning parts

- Bolt loose or missing
- Back head gas pressure

13
SAFETY INFORMATION

BREAKER INSTALLATION

Breaker should be installed to the correct specification excavators. If the breaker is too heavy for
the excavator, it could be overturned during operation. Thus, the breakers should be installed as
CAT recommends. The installer should refer to the breaker operation manual for proper
installation. In case of using quick coupler, operator should check the specification of total
working weight including the weight of quick coupler.

CHECK THE QUICK COUPLER ATTACHMENT STATUS

Quick coupler attachment status to the breaker should be checked before operation when the
breaker is assembled to the excavator with quick coupler. If the breaker is detached from the
quick coupler during operation, it could cause serious injury or death. Operator should check the
coupling status between coupler and breaker. Also quick coupler safety pin must be installed
before operation.

HYDRAULIC HOSE CHECK BEFORE OPERATION

Hydraulic hose damage or joint part loosening could lead to serious injury or death by oil leakage.
Operator should check the hydraulic hose and joint parts carefully before operation. It is high
recommended to use CAT standard hydraulic hose or comparable ones which can meet the
breaker operation pressure in a good capacity.

CORRECT OIL FLOW AND PRESSURE SETTING

Breaker and excavator have different operation pressure and oil flow respectively. If the oil flow
and pressure deviate from each equipment specification, excavator vibration or hose shaking
could damage hydraulic hose. Proper oil flow and pressure should be set based on the operation
manual. Operators should always communicate with the product manufacturer regarding oil flow
and pressure setting.

14
SAFETY INFORMATION

3. PRECAUTION DURING OPERATION

SECURE BRIGHT OPERATING SITE

Check if the operating site is bright enough to work. Operators should stop until they can secure
a clear view enough to operate machine when it is hard to work due to fog, rain or snow.

DOWNTOWN WORK

It is very dangerous for unauthorized person to access the work site. Stand <no entry> signpost
and barrier if the worksite is located near the downtown. Security personnel should be also
needed at downtown work.

SUPERVISOR INSTRUCTION OBSERVATION

Supervisor instruction should be followed at the work site for safety. Supervisor should be in the
dangerous area at the work site. Operators should follow the instructions of the safety supervisor.
Safety supervisor should be present at the work site, especially in dangerous area.

OPERATION LEVER PEDAL AND SWITCH CHECK

Each specification of lever, pedal and switch are different by manufacturer. Operator should
check operating switch, lever and pedal before the breaker operation. If the excavator has
changeable system by operation mode operator should understand related function before
operation and check the system at the safe place.

BE AWARE OF OPERATION AT THE SLOPE.

Main carrier may overturn while operating on a slope due to instability. To avoid this, operator
should drive slowly on a slope. Also, maintain height of the breaker lower than on flat ground.
(held 20~30cm above land surface)

ELECTRIC SHOCK WARNING

High Voltage Cable access can cause electric shock with serious injury or death. Breaker
operation should be operated as far as possible from the electric cable. Before operation, ask
electric company for technical support to protect machine and person safely.

VENTILATION IMPORTANCE

Operation without proper ventilation could lack of oxygen or difficulty in breathing caused by
exhauster gas or dust from breaker blow. Install ventilation pipe or open the window for fresh air.

15
SAFETY INFORMATION

CHECK DIRECTION OF TRAMMING MOTOR

Improper operating of travel lever may cause serious injury. Before traveling, check the direction
of traveling motor. If the traveling motor is positioned at the front side from the operator’s seat,
the main carrier should travel in the reverse direction.

OPERATE CAREFULLY WHEN ROTATING EXCAVATOR

Generally, excavator has higher horizontal stability than vertical stability. Sudden turning side may
cause overturning of excavator.

BE CAREFUL OF UNDERGROUND UTILITIES

Before breaker operation, pre-check the location with related authorities of gas pipes, water
pipes, cables, and other underground utilities.

DO NOT OPERATE THE BREAKER AT THE STROKE END OF EXCAVATOR CYLINDER

When operating breaker with the cylinder of excavator arm, boom, and bucket at the stroke end
position, the cylinders will be damaged by strike impact and pressure. Also the boom can be
separated and it may cause serious injury or damage.

BE CAREFUL OF SOIL PILE

If operating excavator on a soil pile, the pile may crumble by weight and vibration of excavator.
Operate the excavator carefully at a pile work site.

DO NOT OPERATE ON CLIFF

When operate breaker on cliff or bank, excavator could fall down and serious injury or damage
can be caused. Do not operate in such conditions to avoid collapse

16
SAFETY INFORMATION

WARNING FOR FALLING ROCKS

When operates breaker close to the high cliff, serious damage or accident can arise due to fallen
rocks or landslide. When breaking objects at the cliff, excavator should be parallel to the cliff.
Operator should be ready to jump out immediately at emergency case by putting driving motor
back side.

SAFE DRIVING

If possible, it is good to drive the excavator at the flat land to prevent any accident. Tool edge
should be 40 ~ 50 cm higher than the land. The equipment should be distant from the electricity
pole, building, or obstacle. Be careful to travel slowly in the snowy or freezing area. Excavator
could be overturned by the sudden start or stop from the unstable land surface.

WARNING FOR FLYING & FALLEN ROCKS

Rocks or other breaking object could be fallen from unexpected direction which could cause
serious injury or death. Operators should always be careful for the fallen rocks from unexpected
direction and install over head guard at the excavator.

IMMEDIATE ENGINE STOP WHEN OIL LEAKAGE IS FOUND

If operator finds oil leakage from the breaker hydraulic hose or excavator operation system, stop
operation immediately and fix the leakage part.

USE THE BREAKER ONLY FOR THE SPECIFIED WORK

If using the breaker for crane work or suspending heavy objects, serious injury, an accident, or
death may occur.

COLLISION WARNING

Operator should be careful for the collision at indoor or narrow work place.

17
SAFETY INFORMATION

4. PRECAUTION AFTER OPERATION

CAUTION FOR FUEL INJECTION

Flammable fluid such as fuel and oil has explosion possibility and should be handled carefully.
Keep away flammable material from equipment. Do not smoke when inject fuel. Stop engine
completely after fuel injection infect fuel and lubricant at the open area.
Be careful not to over flow fuel tank and other storage.

SAFE PARKING

Park the excavator on flat and solid ground. Put the breaker down on the ground and hold the
track with supporting bar to prevent excavator from moving.

ROAD PARKING

When you park excavator on the road, place fence and warning sign to be visible in dark.

KEEPING SAFE FOR EXCAVATOR

Operator should follow safety guideline set by manufacturer when he leaves work site as follows.

- Parking excavator on the flat and solid floor

- Pay attention not to move excavator by itself
- Place all levers in neutral position
- Step down from excavator after stopping engine completely with key
- lock the door to prevent unauthorized person's operation

18
 OPERATION

WARNING

Be sure to fully understand the contents of “OPERATION MANUAL”.

Improper operation by ignorance or negligence the guidelines will
cause serious injury or death.

19
OPERATION

1. HAMMER INFORMATION

1-1. PART NAME & STRUCTURE

< B35 >

20
OPERATION

1-2. GENERAL SPECIFICATION

B35
MODEL
UNIT TOP MOUNT SIDE MOUNT
DESCRIPTION
DB Linkage TB Linkage DB Linkage TB Linkage

WORKING
kg 3077 3134 2894 2972
WEIGHT

IMPACT RATE bpm 250~550

OPERATING
bar 160~180
PRESSURE

RELIEF
bar 240~250
PRESSURE

OIL FLOW l/min 180~220

BACK PRESSURE Bar 10

TOOL
Mm 153
DIAMETER

PRESSURE LINE
mm 32
SIZE

RETURN LINE
mm 32
SIZE

SUITABLE
ton 30~40
CARRIER WEIGHT

ACCUMULATOR
bar 60
PRESSURE

BACK HEAD
bar 9
PRESSURE

OIL ℃ -20~+80
TEMPERATURE (℉) (-4+176)

VISCOSITY cSt 1000~15

※ Working weight includes standard tool and top bracket

21
OPERATION

1-3. ADVANTAGE OF "B-SERIES" BREAKER

1. SIDE ROD NUT

Less threads damage control by ant-seized greasing application.

2. SIDE ROD (THROUGH BOLT)

Longer life by high quality material & heat-treatment know-how.

3. AUTO GREASE SYSTEM

As standard, automatic greasing line built-in from top to bottom of hammer and
greaser is optional.

4. BACK HEAD
Bigger N2 gas chamber.
(High volume back head provides greater power)

5. PISTON
Piston design provides better performance and oil retention resulting in better seal
life.

6. OIL CONTROL VALVE

Simple and effective valve provided reduced pulsation, and low maintenance cost.

7. PRESSURE CHECK POINT

Easy check-up for hammer operating condition.

8. STROKE CONTROL VALVE

BPM adjuster (tor primary breaking job / secondary breaking job)

9. ACCUMULATOR
Protect carrier hydraulic circuit by absorbing pulsation spikes created during firing
stroke.

10. HOUSING
Reinforcement plates at bottom part.

11. PRODUCTIVITY
Optimized chisel (tool) length & design by high grade steel and heat treatment
provides high out-put.

12. MAIN PARTS

Quality materials and processes used in manufacturing components.
e.g. Cylinder, Back head, Piston, Tools.

13. UNDER WATER APPLICATION

With a simple air-compressor application, you can easily operate our hammer
under the water.

14. DURABILITY
Hammer design, manufacturing practices, quality inspection and testing of
hammers provides durability required for tough applications

15. EASY MAINTENANCE

Easy access and maintenance of tool and bushings provides superior maintenance
capability in the field.

22
OPERATION

1-4. FUNCTION & FEATURES

SEAL HOUSING
VALVE BLOCK
BACK HEAD
ACCUMULATOR

CYLINDER

PISTON

FRONT HEAD

TOOL BUSHING

TOOL

SIDE ROD

UPPER BUSING

TOOL PIN
BUSHING PIN

< BACK HEAD>

The oil pressure connection port and gas charging valve are built into the back head and the
back head is charged with N2 gas.

23
OPERATION

< ACCUMULATOR >

GAS CHARGING PORT

The accumulator compensates for the pressure in the hydraulic circuit and minimizes pulsation.
The accumulator is charged with N2 gas and sealed with membrane.

< VALVE BLOCK >

ADJUST BOLT

The main spool is built into the valve block and controls piston movement. As this spool is pilot
control type, the efficiency and reliability are improved. Also valve adjuster which controls
adjustment of operating pressure is installed in the valve block

24
OPERATION

< SIDE ROD >

The front head, cylinder and back head are secured with the four side rod
rods.

UP SIDE
UP SIDE

< CYLINDER >

The cylinder provided guidance for piston during operation and adjustment of stroke can
be done with adjustment bolt. Cylinder adjust bolt provides frequency control by
changing length of piston stroke and frequency can be controlled, meanwhile keeping
working pressure and flow rate of oil fixed.

25
OPERATION

< FRONT HEAD>

The front head contains the upper bushing

and lower tool bushing which function to
absorb shock and align tool for correct
contact with piston.
The front head is so designed that each
component can be replaced.

Tool bushing protects the front head and

guides the tool.
Tool bushing can be replaced only by
removing the tool bushing pin.

< PISTON >

The piston kinetic energy is converted into hammering energy to break rock.
Important factors are the hardness, toughness and surface finish.
To allow the piston to prove its merits even under severe conditions, a special alloy is
used and the piston is hardened by special heat treatment. Further, the surface of piston
is super finished to result in improved hammering force.

NOTE
The piston is NOT chromed and cannot be chromed as a repair process.

26
OPERATION

<TOOL>

Use a tool suitable for the application

TYPES & APPLICATION

TYPE OF TOOL SHAPE GENERAL APPLICATIONS

Multi-use
use application
application,
MOIL breaking hard rock. concrete
and bedrock
bedrock, etc.
Breaking concrete
concrete, bedrock,
CHISEL trenching, and operation on
slopes.
Breaking concrete
concrete, bedrock,
BLUNT trenching, and operation on
slopes.
Multi-use
use application
application,
CONE breaking hard rock
rock, concrete
and bedrock
bedrock.

※ CAT offers 4 major types of tool. Those types are mostly and often used at the job site.
According to the working conditions and the objects to break, make a proper choice of tools.

DIMENSIONS & SPECIFICATION

MODEL
UNIT B35
DESCRIPTION

TOOL DIAMETER (A) mm 153

TOOL LENGTH (B) mm 1400

EFFECTIVE LENGTH (C) mm 735

TOOL WEAR LIMIT (D) mm 450

WEIGHT kg 175

27
OPERATION

1-5. EXTERNAL DIMENSIONS OF EACH MODEL

< B35 OPEN HOUSING > < B35 HAMMER >

28
OPERATION

2. INSTALLATION & REMOVAL OF BREAKER

WARNING
Failure to heed this manual can lead to premature failures, product damage, personal injury or
death. Do not install or perform the machine and the hammer until you have understood and
follow the required information and regulation for the machine and the hammer.

2-1 KEY POINTS FOR SELECTING HAMMER

Below is basic guideline for selecting the proper breaker and the main carrier on which it will be
installed.

1) CONSIDERATION OF MAIN CARRIER SIZE

The breaker must be selected properly for optimum performance and the mounting capability.
First, consider the application work, and then decide the main carrier which size of breaker will
be mounted. If the operating weight of the main carrier can meet within the range of breaker, the
main carrier can hold the weight of breaker enough.
If the weight of the breaker that you want to install is out of the recommended range, contact
manufacturer or your CAT technical engineer for more information.

2) LIFTING CAPACITY

The weight of the breaker must not exceed the maximum lifting capacity. The main carrier is
always required to maintain its balance at any position. Most excavators, backhoe, or skid
loaders have their own provided value of lifting capability. Keep in mind that the maximum lifting
capacity of main carrier is the lowest when the boom of carrier is at full each.

3) OIL FLOW

For optimum performance, the setting of oil flow is important before operation. Breaker will
operate within a required range of oil flow, and this range is specified for each breaker. Check if
the main carrier has enough capacity of supplying oil flow to avoid abnormal operation of breaker.

29
OPERATION

2-2 HYDRAULIC CIRCUIT

Hydraulic oil flow and pressure are needed to operate the hydraulic breaker. The hydraulic oil
pipe line in the main carrier should be directed out the left side of the boom and the return line
on the right. The hydraulic breaker will operate within a required range of oil flow. The operating
pressure will depend on the amount of oil flow, the return line pressure.

30
 OPERATION

2-3 INSTALLATION

1) DIMENSION OF TOP PLATE

Following is dimension of top plate. Use those data when preparing for the top bracket which is
mounted on the main carrier.

< B35>

UNIT : mm

MODEL A B C D E F G H I J K L

B35 12-∅39 175 220 175 730 130 275 - 635 50 80 -

31
OPERATION

2) TOP BRACKET ASSEMBLY

WARNING
To remove or install breaker from or to main carrier at the slope or unstable surface could cause
serious injury or death. Disassembling or assembling should be done at the flat land without any
obstacle or men.

1. Stand the hammer vertically on the stable ground or service pallet with housing assembled.
2. Tighten the top cover bolts (No.2 to No.4 bolts assembly) to fix the bracket to the housing.
3. All the bolts should be tightened with torque wrench. The torque value and the size of
each model are as follows :

< B35 >

1. TOP BRACKET 2. HEX. BOLT 3. PLAIN WASHER

4. HEX. NUT

32
OPERATION

WARNING
At least two persons (one is the operator of main carrier) are needed for installing and removing
the breaker. Always check and follow the signals for operation in advance.
Be sure to use a crane to handle pins, brackets, bushes, and other heavy parts.

< “B-SERIES” top bracket torque table>

MODEL B35

Top bracket Bolts

M36X4.0PX150L
Specification

Torque (N.m) 2800

3) PIPE FLUSHING

After setting of relief pressure finished, open both of stop valves and push the pedal to flush the
hydraulic oil pipe line. This operation is very important for breaker and the main carrier to remove
the dirt, dust, little particles in the piping. Flush sufficiently for at least 20 minutes. For efficient
flushing work, press down and sometimes release the pedal for pulsation to pipe line.
After flushing work, discharge air from the hydraulic oil tank, clean the line filter and remove the
foreign particles.

STOP VALVE

33
OPERATION

4) INSTALLATION OF BREAKER

DANGER
Operator should pre check any possible dangerous part when he install or remove the mounting
pin.
Be careful not to put arm or finger into the pin hole and not to touch pin with hand nor hit the pin
too strongly.
Do not stand in front of pin during disassembly. Wear goggles when hammering pin to
disassemble.

After fixing the top bracket to the housing, prepare for installing tthe breaker to the main carrier.

1. Slowly move the operation lever of the excavator to align the pin holes of the arm end with the
bracket(4).
pin hole of the breaker's top bracket

2. Insert the mounting pin (4) from the left side so that the Hex. bolts (6)) can be seen from the
operator seat.

3. Insert the mounting pin (3) into the pin hole, set the stopper (5) and attach the Hex. bolt (6).

1. Hydraulic Breaker
2. Excavator arm
3. Mounting pin (Arm side)
4. Top bracket
5. Stopper
6. Hex. bolt
7. Double nut

34
OPERATION

4. Tighten the Hex bolt (6) with double nut (7).

5. Extend the bucket cylinder (8) so that the mounting pin (9) can be inserted through the bore
of link.

6. Insert the mounting pin (9) into the pin hole, set the stopper (5) and attach the Hex bolts (6).
(Same as procedure No.3)

5. Stopper
6. Hex. bolt
7. Double nut
8. Bucket cylinder
9. Mounting pin ( Link side )

WARNING
When the stopper attached to the pin is missing, it may detach breaker from the excavator.
Operators must check pin stopper attached proper
properly
ly before and during operation.
Breaker detachment from the main carrier while working could cause serious injury or death.

NOTICE

Secure Hex bolt by double nut, periodically Check the looseness of double nut during operation.

35
OPERATION

5)) CONNECTING IN/OUT LINE HOSE

1. Stop the engine of the main carrier, discharge pressure from the hydraulic oil tank and d
do not
move the operation lever.
2. Check that stop
op valves on both side of the arm are fully "CLOSED". If not, use the spanner and
turn
urn them to the close position.
3. Remove the union cap and hose plug from the breaker pipe line attached to the end of the
arm.

NOTICE

Pay attention to keep the union cap and plug clean. Dust or particles can cause the
contamination of hydraulic oil and result in serious damage of breaker and excavator.

on
4. Connect the "IN" & "OUT" hoses to the stop valves o n both sides of arm and secure.

5. Fully open the stop valves at the high and low pressure sides to connect the hydraulic circuit.

1. Stop valve
2. In - line hose (High pressure)
3. Out - line hose (Low pressure)
4. Union cap
5. Hose plug

CAUTION
When connecting or disconnecting oil hoses, prepare the metal pail and put it under to prevent
spilt oil.

36
OPERATION

6) CONNECTION PORTS OF THE HAMMER

1. IN - LINE hose (High pressure)

2. OUT - LINE hose (Low pressure)

< B35
35 >

Following is the specification of IIN / OUT port in the fort fitting size.

HOSE ASSEMBLY PORT FITTING SIZE

MODEL REMARK
IN OUT IN OUT

B35 PT 1 1/4″″ PT 1 1/4″ UNF 1 11/16 UNF 1 11/16

37
OPERATION

2-4 REMOVAL OF BREAKER

WARNING
To remove or install breaker from or to main carrier at the slope or unstable surface could cause
serious injury or death. Removal or installation procedure should be done at the flat land without
any obstacle or men.

CAUTION
When connecting or disconnecting oil
oil-hoses,
hoses, prepare the metal pail and put it under to prevent
spilt oil.

1. Lay down the breaker with valve block (control valve) facing upwards on th
thee flat, safe place.

2. Stop the engine of main carrier, and release the pressure trapped inside the hoses and oil
tank.
Wait ten minutes for oil pressure to drop.

3. Turn the stop valves (1) of both side

sides to the fully closed position.

4. Remove the oil hose. (The residual pressure may remain in the pipe
pipe-line.
line. Loosen the oil hose
joint little by little to release the residual pressure)

5. After removing hoses, tighten the union caps (4) and hose plugs (5) securely to avoid oil
contamination. (Prevent the dust or particles from entering)

1. Stop valve

2. In - line hose (High pressure)

3. Out - line hose (Low pressure)

4. Union cap

5. Hose plug

38
OPERATION

6. Loosen the double nuts (7) at the link side and remove the Hex bolt (6) and stopper (5).

7. Pullout the mounting pin (9) (link side)

※ If the pin cannot be removed easily, slightly move the main carrier arm for easy removing.

5. Stopper

6. Hex. bolt

7. Double nut

8. Bucket cylinder

9. Mounting pin (Link side)

DANGER
Operator should pre check any possible dangerous part when he install or remove the mounting
pin.
Be careful not to put arm or finger into the pin hole and not to touch pin with hand nor hit the
pin too strongly. Do not stand in front of pin during disassembly. Wear goggles when
hammering pin to disassemble.

8. In the same way, loosen the double nuts on the arm side, remove the Hex bolt and stopper,
and pull out the mounting pin.

9. Be sure to check the condition of mounting pin, bushing whether they are worn out or
damaged. Also, check the condition of arm and link.
(If there is a problem with them
them, replace or repair)

10. Start the engine, and slowly operate the M

MCV to check the oil leakage from the pipe line.

39
OPERATION

NOTE
Nitrogen charge must be installed prior to initial start up of hammer.
NOT charge from factory

2-5. CHECK POINTS WHEN SETTING HYDRAULIC LINE TO BREAKER

1) RELIEF PRESSURE

Remove high pressure hose from hammer INLET and connect to return line ball valve with test
gage installed. Close return line ball valve to dead head oil and measure auxiliary relief valve
setting(Maximum setting 25000 kPa).

2) OIL FLOW AND OPERATING PRESSURE

l Stop the carrier engine. Assemble the high pressure gauge on the hammer (350 bar gauge)
measuring port.

l Start the engine. Set the tool of the breaker for example on a thick steel plate. Adjust
operating engine revolution and start to operate the breaker.

l Read the average pressure from the high pressure gauge of operating pressure.

l Stop the carrier and remove the gauge. Tighten the plug of the pressure measuring port.

3) PIPE LINE CONDITION

l When installation of pipe line is finished, specially check as below

- Tightening of control valve bolts, oil filter, relief valve

- Tightening of pipe fitting, plugs
- Retighten the hose fitting, if the hoses are twisted

40
OPERATION

2-6. OPERATION PROCEDURE

WARNING
It may cause serious injury and death when operators do not follow operation manuals and
warnings. Operators should not overlook the guidelines of which they don't understand and
should fully understand all safety guidelines and warnings before operating machines. Operation
manuals and warnings are very important for safety. Operators should maintain those manuals in
a good condition and replace them if damaged.

1) PREPERATION OF SAFE OPERATION

l LINE INSTALLATION
It is very important to install a line for breaker in excavator. Correct oil flow and pressure
setting improves durability and efficiency of the breaker.
Most excavators have two main pumps. It is recommended to use of these two pumps for
hydraulic energy to operate breaker.

l PIPE SPECIFICATION
It is very important to select a right size of pipe line breaker operation. If the pipe is too
smaller than recommended specification, hydraulic system will be overheated. Resistance in
the pipe will decrease efficiency and create an early damage of excavator hydraulic system.

l HYDRAULIC OPERATING OIL MAINTENANCE

Excavator hydraulic operating oil is used for breaker operation, which requires more careful
procedure than general bucket work. In using breaker, excavator hydraulic oil temperature
goes up higher than bucket use. And then the time to change the oil and filter could be faster.
Hydraulic oil contamination could damage not only breaker but also excavator parts, which
needs to be maintained carefully. The oil temperature should not exceed 80°C.
If the working temperature exceeds 80°C, an additional cooler should be installed in breakers
return line.

41
OPERATION

2) PRECAUTION BEFORE OPERATION

l CHECK WORK SITE CONDITION

Operators should check the geological or soil condition before machine operation to prevent
any possible accident.

l EQUIPMENT CHECK BEFORE MACHINE OPERATION

Before starting engine, operator should check the machine condition and replace and
breaking part if any problem found. The following parts should be checked:

- Leakage if the hydraulic system or other functioning parts

- Bolt loose or missing
- Gas pressure (Breaker back head, accumulator)

l WARM UP MACHINE

Do not operate the main carrier right after starting the engine. Leave the machine idling for
warm up. Warm the hydraulic oil sufficiently in cold or for operation. If the operators use the
breaker at the first time, idle engine for a while and operate the breaker with a light load.
Immediate acceleration will break oil film between cylinder and piston.
This may cause seizure or jam. Operate the breaker slowly with a light load until oil film
covers sufficiently between cylinder and piston.

42
OPERATION

2-7. CORRECT OPERATION

BREAKER ROTATING WORK

The followings should be kept to prevent any se

serious injury or death.

- Before rotating excavator

excavator, operator should warn any nearby people by buzzing
- Operators should check any person aside or back side of the excavator
- Signal person should be placed at the blind angle area

WARNING FOR THE SIDE ROTATION WORK

Generally, excavator has higher horizontal stability than vertical stability. Sudden turning side may
cause overturning of excavator.

43
OPERATION

OPERATE THE MACHINE WITH CARE

Operator should concentrate on the operating. Careless operation could lead to s

serious injury
and death.

DO NOT OPERATE ON CLIFF

When operate breaker on cliff or bank, excavator could fall down and serious injury or damage
can be caused. Do not operate in such conditions to avoid collapse.

44
OPERATION

DO NOT OPERATE THE BREAKER AT THE S

STROKE
TROKE END OF EXCAVATOR CYLINDER

When operating breaker with the cylinder of excavator arm, boom, and bucket at the stroke end
position, the cylinders will be damaged by strike impact and pressure. Also the boom can be
separated and it may cause serious injury or damage.

DO NOT OPERATE THE BREAKER

ER BY PRYING

Do not use the breaker for bending or operate at the same spot for a long time. It could cause
serious injury or accident by crashed rocks fallen from unexpected direction or damaged tools.
Operate the breaker properly, otherwise iitt also could cause early damage of vari
various joint parts of
the excavator.

45
OPERATION

PROHIBITION
ROHIBITION OF EXCAVATOR LIFTING

If operator lifts excavator using breake

breaker or tool, tool could slip out from the striking object which
causes a serious injury or death due to the instability of main carrier.

USE THE BREAKER

KER ONLY FOR THE SPECIFIED WORK

If using the breaker for crane work or suspending heavy objects, serious injury, an accident, or
death may occur.

46
OPERATION

PROHIBITION
BITION OF OPERATION UNDER WATER

Breaker should not be operated when the front head is under water. If the operation is required
under the water, an air compressor must be attached to prevent damage.

DO NOT PUSH OR PULL OBJECTS WITH TOOL

Pushing or pulling object with tool could cause early wearing of the tool or breakage
breakage.
Even the bolts of breaker may be broken, the bracket damage, the tool broken.

47
OPERATION

PROHIBITION OF PUSHING OR PULL

PULLING OBJECT WITH BREAKER HOUSING

Operator should be careful in pushing or pulling object with breaker housing because it could
break joint
nt parts or deform the housing.

PROHIBITION OF BLANK FIRING

Operator should always be careful to avoid blank firing which may cause serious trouble or early
damage of the breaker.

48
OPERATION

3. STORAGE

3-1. SHORT TERM STORAGE

If the hammer will be stored for up to two weeks, it is regarded as "Short term storage". Following
is the instruction how to store the breaker.

Store the hammer indoors with good ventilation and drainage.

l Place the hammer in a vertical position. If avoidable, store it horizontal on the wooden block
(Mounting end should be higher than the lower end of the breaker)

l Disassemble the breaker from the boom of excavator

l Clean the exterior of the breaker

l Seal with plug cap on hose end

l Dismantle the tool, and apply grease to piston bottom, tool bushing, tool pin, the inside of
front head

l After sufficient greasing, re-install the tool, and cover with the waterproof tarpaulin (tarp)

< WELL VENTILATED AND DRY INDOORS >

< B35 >

49
OPERATION

3-2. LONG TERM STORAGE

If the event of long term storage (longer than six months), carry out following procedures.

l The breaker must be stored standing up in a vertical position. If unavoidable, store it

horizontal on the wooden block.

l Store the hammer in a sufficient airy room, if avoidable to store outdoors, place it with good
ventilation and drainage, and cover with a tarp.

n Standing up
l The breaker must be stored in a storage-stand
l Clean the exterior of the breaker, and check out each part for defects
l Dismantle the Tool, and apply grease to piston bottom, tool bushing, tool pin, inside the
front head
l Remove the gas pressure from back head
l Load the hammer by letting the tool or fixture on the stand push the piston up into the
cylinder.
l Seal the high-pressure supplying port with plug
l Cover with the waterproof tarpaulin (tarp)

※ “A” = Height of stands

MODEL “A”(mm)

B35 796.5

50
OPERATION

3-3. OPERATION AFTER LONG TERM STORAGE

Generally, when operating the breaker which is stored for a long period, careful inspection must
be carried out before using. Moreover, after long term storage, oil film could be broken naturally.
Or sudden operation under high pressure can also cause seizure due to the breakage of oil film.

Before starting the breaker, slow operation at idle mode will not only prevent the breakage of oil
film, but protect the piston and cylinder against seizure.
Following is the instruction how to inspect the breaker.

l Before starting operation, remove the tool and check the corrosion on the piston bottom.
l In the event of horizontal storage for a long period, check deformation of seals on hammer
before using.
l Warm up the hammer at idle for 10~15 minutes without nitrogen gas in the back head.
l Check the regularity of hammer frequency during warming up.
l Check the hose and pipe line for oil leakage and damage.
l When all are in good working order, charge the gas in the back head, and then start operation.

51
OPERATION
4. TROUBLE SHOOTING
The table below is prepared for the person in charge of maintenance to be able to take corrective
measures immediately when the breaker trouble occurs. When trouble has occurred, check
conditions shown below, and contact our dealer.
Situation
1. No blowing
(1) No hydraulic oil supplied to
breaker.
(2) Sufficient hydraulic oil
supplied to breaker.
2. Blowing, but weak breaking
power.
(1) Insufficient hydraulic oil
supplied to breaker.
Cause
(a) Failure of hose and pipe
(b) Stop valve is closed.
(c) Failure of operation valve
system
(d) Insufficient hydraulic oil
(e) Failure inside the breaker
(f) Nitrogen gas pressure at the
back head is excessively
high.
(a) Failure of hose and pipe
• Clogged piping system
• Oil leakage
(b) Failure of operation valve
system
• Deformed pedal
• Deformed control cable
• Galling control valve
(c) Insufficient hydraulic oil
(d) Contamination and
deterioration of hydraulic oil
(e) Pump out of order
(f) Drop of the relief valve
pressure
52
Correction
(a) Inspection, repair, or
replacement of piping system
(b) Open stop valve.
(c) Inspection, repair, or
replacement of valves
(d) Add oil into the oil tank until
specified level.
(e) Ask the dealer for inspection
and maintenance.
(f) Adjust the nitrogen gas
pressure.
(a) Inspection, repair or
replacement of piping system
(b) Inspection, repair, or
replacement of operation
valve system
(c) Add oil into the oil tank until
specified level.
(d) After cleaning the tank,
change the oil completely.
(e) Ask the excavator dealer for
maintenance.
(f) Ask the excavator dealer for
maintenance.
OPERATION
Situation
(2) Sufficient hydraulic oil supplied
to breaker.
(3) Weak impact power and
excessive hose vibration.
3. Weak impact power and
excessive hose vibration.
4. Oil leakage from the front head or
bottom of tool increases.
5. Cylinder adjuster
(1) Oil leakage from cylinder adjuster
area
(2) Sudden increase of piston stroke
6. Valve adjuster
(1) Oil leakage from valve adjuster
area
(2) The breaker impact power
weakens, and operating pressure
decrease
(3) No blowing but sufficient
hydraulic oil supplied to breaker
Cause
(f) Failure of the inside of
cylinder
• Entry of foreign particles
(g) Drop in nitrogen gas pressure
at the back head
(h) The cylinder adjuster is kept
open.
(a) The accumulator of the
breaker body is defective.
• Gas leakage
• Breakage of membrane
(b) Drop in nitrogen gas pressure
at the back head.
(c) The cylinder adjuster is kept
open.
(a) Abrasion of the cylinder seal
(a) Damage of O-ring or backup
ring from the adjust bolts
(b) Damage of threads of adjust
bolt
(a) Damage of O-ring or backup
ring from the adjust bolts
(b) Damage of threads of adjust
bolt
(c) Valve adjuster could be fully
closed.
53
Correction
(f) Ask your dealer for an
inspection.
(g) Adjust the nitrogen gas
pressure.
(h) The cylinder adjuster of
blows.
(a) Ask the dealer for
inspection and
maintenance.
• Fill the gas or replace the
membrane
(b) Adjust the nitrogen gas
pressure.
(c) The cylinder adjuster of
blows.
(a) Ask the dealer for an
inspection.
• Check if the normal
lubricating grease flows out
of the tool or if by hydraulic
oil flows out.
(a) Replace the of O-ring or
backup ring
(b) Replace the cylinder adjust
bolt
(a) Replace the of O-ring or
backup ring
(b) Replace the valve adjust
bolt
(c) set at the position of 2.5
times counter -clockwise
turning
OPERATION

5. OPERATING PRINCIPLE

STEP 1

1. Before oil flow is supplied at the stage,

operating valve is at the lower position
position.

2. If high pressure oil flow is supplied, there

would be high pressure at the bottom side of
cylinder, in accumulator and in high pressure
chamber of valve.

3. If high pressure oilil flow is supplied, the oil

flow at the bottom of cylinder
inder will make
piston goes up.

4. When piston goes up, then the chamber of

N2 gas at the back head compresses, so
load pressure at the bottom of cylinder
comes into being. At the moment, the same
pressure occurs in accumulator, high
pressure oil is stored up in Accumulator as
gas chamber of accumulator
lator compresses.

54
OPERATION

STEP 2

1. When piston going up and approaching at

the highest point, A1 of the piston rises up to
the cylinder conversion chamber connect to
each other, and then oil pressure converts
into high pressure. "A"

2. Surfaces A3, A4 and A5 are now under high

pressure.

3. Since A3 < A4 + A5, the valve moves up.

4. With this piston at the highest point, N2 gas

in back head and in the accumulator
compress to the maximum.

A5

A3

A4

DETAIL A

55
OPERATION

STEP 3

1. The high pressure chamber of the valve

connects to the high pressure chamber of the
accumulator when valve rises up. At this
moment, the top of the cylind
cylinder converts into
high pressure.

2. Even though the bottom and the top of the

cylinder are high pressure, piston is on the
downward
ownward movement because area o on the
upper side of the piston is bigger than the one
on the lower
er side of the piston (A2 > A1) and
because of the N2 gas pressure in the back
head.

3. As piston is going down, hydraulic oil coming

out through the bottom of the cylinder
cylinder, another
hydraulic oil supplied from pump and hydraulic
oil that is filling up when accumulator
cumulator is in
expansion connect to the pressure chamber of
the valve.
And they flow through
ough the upper of the cylinder.

4. Accumulator is s for preventing the upper side of

the cylinder from a pressure drop as it fills up a
vacancy of the upper of the cylinder
cylinder, occurred
by piston drop at high speed
speed, with hydraulic oil.

56
OPERATION

STEP 4

1. Just before the piston goes down and hit

the tool, piston cuts off the connector of
the Valve.
So, conversion chamber of the valv
valve is
turning into low pressure.

2. Keep in your mind that valve connector for

high pressure is always high pressure
pressure, so
the valve is going down.

3. This process
cess occurs in very short time.

4. As valve starts to go down at the same

time.

57
OPERATION

6. SPECIAL APPLICATION

6-1. UNDERWATER JOB

1) PRINCIPLE OF OPERATION
Although the piston sliding section of the hydraulic hammer is sealed everywhere, water will enter
into the area where the piston and the chisel with impact each other, when used in underwater
job.

When the hammer is used in this condition, the piston is forced against the water.
Therefore, part of the water that is equal is volume to the piston stoke can find no way out except
through a small clearance between the chisel and the bushing.
During that time, the water is discharged with extremely high pressure and velocity, which will
damage the hydraulic hammer in a short period of time.
The water will also get into the hydraulic system of the excavator, causing damaged to the pump,
etc.

2) COMPRESSOR CAPACITY AND SUPPLIED AIR PRESSURE

(1) Compressor capacity varies with the hammer models.

AIR PRESSURE
MODEL
bar Psi

B35 3~5 43~72

(2) Setting of supplied air pressure depends on the working depth of the hydraulic hammer used.

DEPTH AIR PRESSURE (bar)

To 10m 22

To 20m 37

58
OPERATION

PROCEDURES FOR
R SUPPLIED AIR PRESSURE SETTING

WARNING
Do not supply the compressed air 6bar (87ps
(87psi)) from the compressor to the hammer directly,
otherwise the air may be forced into the hammer through the sealed area.
Be sure to reduce the pressure of the compressed air with the regulator as instructed above.

1) After installation of the underwater piping, operate the compressor to supply the air to the
pressure with
hammer before it is submerged in the water. Maintain the air pressur ith the regulator at this
time.

2) Extend the boom and the arm of the hydraulic excavator up to the maximum working depth
used in the job site and keep the hammer submerged in the water.
Be sure that bubbles are generated from the chisel area due to air supply.

3) While maintaining the above condition, reduce the air pressure with the regulator and set the
supplied air pressure at the minimum level required to produce bubbles. Bubbles should be
still produced even in this state.

59
OPERATION

3) PRECAUTIONS FOR OPERATION

WARNING
Operate the hammer more carefully underwater because the hammer is exposed to severe
condition and environment of the water.

before putting hammer in the water.

Air compressor must be running befo

carrier
Do not shut off air while hammer is under water. Damage to hammer and contamination of carrie
hydraulic circuit may happen.

(1) At the starting the hammer which has been stored for a long term, place the hammer vertical
clearance between the tool bushing.
and take out the hydraulic oil from a clea

(2) Supply the compressed air into the hammer.

(87psi).
(3) Start to operate the hammer after the compressor pressure reaches 6bar (87ps

(4) Stop the hammer immediately and determine the cause if the air supply stopped during
operation. In case off it, there will be no bubbles.

3>, and check the bubbling point.

(5) Lay the hammer in the water as <FIG 3>

(6) Do not hammer in the same position for a long time. In case of the excavator is on a barge,
the tool is liable to break because the down force and the force of away from the barge are
able to make damage on the tool easily.

grease
(7) Grease the tool more than ordinary lubrication because the greas e is blown off by supplied
air.

< FIG 3 >

60
OPERATION

4) STORAGE

WARNING
Perform routine maintenance before storage. Otherwise, the hammer will have corrosion and be
damaged in the underwater job.

(1) FOR SHORT TERM STORAGE

A) In order to drain water completely away, operate the hammer in land for several minutes
der to drain water completely.
during supplying the air in order

B) If it is difficult to operate the hammer on land as the above, run the engine at low RPM idle the
hammer 5 to 6 times during maintaining air supply.

< FIG 4 > < FIG 5 >

(2) FOR LONG TERM STORAGE

A) Wash the hammer outside clean and carry out the maintenance for short term storage as
en place the hammer as <FIG 4>.
above, then

bushing <FIG 5>.

B) Then pour one liter of hydraulic oil into a clearance between the tool and tool bushi

e tool and the tool bushing with a waterproof tarpaulin (tarp).

C) Cover the

61
OPERATION

5) SAFETY DEVICE
In order to minimize the risk of water entering the hammer, a pressure switch must be added to
the hammer circuit. The purpose of this connection is to stop the hammer immediately, if the air
pressure decreases below
low the adjusted minimum level.

The safety device can be fitted according to following

scheme:

< SYMBOL >

OPERATING
FILTER AIR DRYER
VALVE

OPERATING
COOLER OIL PUMP
SWITCH

RELIEF PRESSURE AIR

VALVE SWITCH COMPRESSOR

62
OPERATION

6) MAINTENANCE INTERVALS IN UNDERWATER APPLICATIONS

The Caterpillar hammer can be used in an underwater application, modifications are required
(See special instructions on page 58). During underwater operation, the hammer must be
inspected every half hour operation.

Adapt the inspection intervals to working conditions.

AFTER EVERY HALF HOUR OPERATION

A) Grease the tool shank and tool bushing through grease nipples.
B) Check all hoses and connections.
C) Check the operation of air pressure switch.

DAILY MAINTENANCE

A) Remove the retaining pin and the tool for inspection. Grind the burrs away if necessary.
B) Check that the tool has received sufficient grease.

HAMMER SERVICE AFTER UNDERWATER JOB

A) The hammer must be totally dismantle and serviced after working underwater. Clean and check
all hammer parts and either replace or repair damaged parts.
B) Assemble the hammer with new seals.
C) Neglecting hammer service after underwater work can cause severe damage to the hammer.
The piston could rust even in a few days depending on the environment.

7) PRODUCTIVITY IN UNDERWATER APPLICATIONS

In underwater applications, the productivity of a hydraulic hammer is considerably lower than in

normal work. This is caused by :

A) The breaking object is not visible to operator. This causes misalignment between tool and
object and unnecessary idle strokes.
B) Hammer must be inspected and greased more often than in normal work.

63
 MAINTENANCE

NOTICE

Be sure to fully understand the importance of “MAINTENANCE”.

Regular inspection must be carried out as required maintenance
schedule. Negligence of inspection will result in excessive owning
and operating cost.

64
MAINTENANCE

Maintenance manual provides personal guide line to keep the breaker operating in best condition.
Check every part and component of the machine before and after operating the hydraulic breaker
for extending machine's life. Keep in mind how to maintain your breaker.

1. GENERAL PRECAUTION

REGULAR EQUIPMENT CHECK UP

Regular equipment check up is required to prevent equipment from breaking.

Check up result should be recorded for future maintenance.

FOLLOWING MAINTENANCE SAFE GUIDELINE

Operator should follow the safe guideline related regular check up and maintenance, otherwise
he may have serious injury or death. Operator should wear safety gear before equipment check
and follow safety procedure.

SAFE CLOTHES AND PROTECTION GEAR

Equipment check and maintenance without safety gear may cause burn, fall, eye sight damage,
serious injury or death. Operator should always wear eye protection goggle, safety hat, safety
shoes & gloves, earplug for hearing protection.
Using hammer or grinder, you should wear goggle and safety mask to protect yourself from
falling steel parts.

FIRE PREVENTION

In checking and maintaining equipment, operator handles flammable materials such as fuel, and
battery. The followings are required.

- Use non flammable detergent

- Fire extinguisher and fire fighting material should be equipped
- Do not smoke during checking and maintaining machine
- Use explosion protection lantern in checking oil and fuel
- Stay away from flammable material during grinding or welding

65
MAINTENANCE

LIGHTING AND LANTERN

Improper lighting creates narrow vision and may cause serious injury. Work site should always be
bright. Do not use spark to light work site because it can blow out battery. Fixed light and
explosion protection lantern should be used when operator checks fuel and battery.

USE RIGHT TOOL

Use right tool for maintenance to avoid any serious injury or accident. Do not use tool or hammer
to prevent steel part from flying. It is highly recommended to use CAT tool.

WORK SITE CLEANING

Work site should be clean and not be contaminated to avoid any accident or injury. Before
maintenance and check, used oil and replaced parts should be cleared from the work site to
maintain clean work site.

EQUIPMENT CLEANING BEFORE CHECK

Damaged or broken parts may not be seen because of the dirt stick to breaker housing.
Breaker housing should be cleaned before maintenance for safe check.

SAFE CLEANING OF EQUIPMENT

The wet floor is very dangerous. Wear non slippery boots when you clean the machine. Wear
goggle and protection gear because the high pressure cleaner may hurt your skin and eye.
Water and steam should not touch with battery, electric connector or electronic parts, which may
cause breaking or electric leak.

CHECK AT THE FLAT WORK SITE

Checking in slope side may not allow accurate check or maintenance, which may cause serious
injury or accident. Breaker checking should be done at solid and safe flat land. Breaker should be
down completely into the floor. Excavator engine should stop and start key should be separated.
Supporting bar should be fixed in the track.

SUPPORT BREAKER SAFELY

Do not fix or replace the hose or joint parts when the breaker is lifted from the land surface.
Breaker should be down to the land or supported by safety bar. Do not work without equipment
supporting bar.

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2. PERIODICAL INSPECTION & SCHEDULE

NOTICE
Read the inspection schedule chart thoroughly and conduct an inspection and repair or replace
the related items for safe use of machine.

NOTE
The times given refer to the machine hours while the breaker is installed.

2-1. EVERY 2 HOURS INSPECTION

1) Grease the tool shank and the tool bushing

2) Observe hydraulic oil temperature, all lines and connections as well as impact efficiency and
evenness of operation.
3) Tighten loose connections.

2-2. DAILY INSPECTION

INSPECTION
ITEM DETAIL PART
• Accumulator bolts
• Side Rod bolts
BOLT
• Top bracket bolts
• Housing joint bolts
SOLUTION
POINT
• Replace the damaged bolts
• Supply the bolt when missing
Looseness
• Tighten to the specified torque
Missing
Damage
Notice: When one side rod is
Falling-off
damaged, recommended to
replace the opposite side rod

PLUG • Rubber Plug Missing

• Replace when damaged
PIN • Tool Pin, Bushing Pin Damage
• Supply when missing
RING • Snap Ring Failing-off

Looseness
PIPE LINE • Piping line of hose joint • Re-tighten to specified torque
OIL HOSE • In/Out line hose Damage • Replace when damaged
Oil leakage

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INSPECTION
ITEM DETAIL PART SOLUTION
POINT

• Check whether the leakage is

caused by grease or hydraulic oil
• Back head seal • If the leakage is caused by
Oil leakage
SEAL • Cylinder seal hydraulic oil, contact your dealer
Gas leakage
• Accumulator seal • Check the gas leakage from back
head using soap bubbles
• Replace the seal promptly

• Replace when wear limit is reached

• If the tool is cracked, deformed,
Cracked, burred, follow the tool warranty
Burred procedure
TOOL • Various kinds of tool
Deformed, • If the degree of damage is not
Broken heavy, repair with a grinder and
reuse.If not, replace with a new
tool

• Before greasing, down pressure

must be applied to push the tool
• Grease port on the up into the breaker
GREASE Greasing
front head • Grease until the grease comes out
around the tool
• Grease the breaker every two hours

• Check the oil condition of

contamination. You can find it with
HYDRAULIC its color
• Hydraulic oil Contamination
OIL TANK • Change the hydraulic oil if oil mixed
with water (Check if the oil has
turbid color)

2-3. MONTHLY INSPECTION

1) Check the tool and tool bushing for wear.

2) Check the hydraulic hoses. Replace if necessary. Do not let dirt get into the hammer or hoses.
3) Check the main carrier's hydraulic oil filter. Change if necessary. Clean oil is very crucial for
proper breaker performance.
4) Check every bolt and nut for the correct torque. Improper or insufficient torque can damage
the breaker.

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2-4. YEARLY INSPECTION OR EVERY 600 HOURS

INSPECTION
PART CHECK ITEM
DESCRIPTION CORRECTION

CYLINDER • Oil leakage • Visual inspection

• Charging gas pressure • Measure the pressure valve

BACK HEAD
• Gas leakage • Check with detection spray

• Oil leakage • Visual inspection

VALVE
• The torque of bolts • Check the torque

• Charging gas pressure • Measure the pressure valve

ACCUMULATOR • Oil leakage • Visual inspection
HAMMER • The torque of bolts • Check the torque
FRONT HEAD
TOOL BUSHING • Check the wear amount • Measure the wear amount
THRUST RING • Check the grease • Visual inspection
TOOL PIN
• Check the wear amount • Measure the wear amount
TOOL
• Check the grease • Visual inspection

SEAL & MEMBRANE • Check condition • Replace

HOUSING
• Check the crack & damage • Visual inspection
TOP BRACEKT
HOUSING
HOUSING JOINT BOLT
• The tightening torque • Check the torque
TOP BRACKET BOLT

• Oil leakage • Visual inspection

OIL HOSE • Check the damage • Check the torque, and
• Check the looseness of joint tighten

PIPE • Mounting bolt looseness • Check the torque

VALIDATE
• Oil leakage • Visual inspection
FLOW& RELIEF VALVE
• Check the relief pressure • Measure the pressure
PRESSURE
RELIEF • Visual inspection
• Oil leakage
VALVE CONTROL VALVE • Valve must be normally
• Check the function
opened and closed
SETTING
• Oil leakage
• Visual inspection
• Check the damage
• Remove the particles
• Check the materials

• Oil leakage • Visual inspection

• Check the lever • Lever must operate normally

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3. HYDRAULIC OIL

※ When the breaker is used continuously, the temperature of the hydraulic oil normalizes at a
certain level depending on conditions and on the carrier. At this temperature, the viscosity of
the hydraulic oil should be 20~40 cSt. (2.90~5.35˚E)
※ The hydraulic breaker must not be started if the viscosity of the hydraulic oil is above
1000cSt(131˚E) or operated when the viscosity of the hydraulic oil is below 15cSt(2.35˚E)

1) When the oil is too thick, the following problems may occur;

a. Difficult start up.

b. Stiff operation.
c. Breaker strikes irregularly and slowly.
d. Danger of cavitations in the pumps and hydraulic breaker.
e. Sticky valves.
f. Filter bypass, impurities in oil not removed.

2) When the oil is too thin, the following problems may occur;

a. Efficiency losses (internal leaks).

b. Damage to gaskets and seals leaks.
c. Accelerated wearing of parts, because of decreased lubrication efficiency.

3) Special oil

※ In some cases, special oils(e.g. biological oils and non inflammable oil) can be used, please
observe following aspects when considering the use of special oil;

※ The viscosity range of the special oil must be in the given range of 15~1,000cSt (2.35~131˚E)

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4) Cleanness of hydraulic oil

※ The hydraulic oil filter of the carrier will clean the oil flowing through the breaker.

※ The purpose of the oil filter is to remove impurities from the hydraulic oil since they cause
accelerated component wear, blockages and even seizure.

※ Impurities also cause the oil to overheat and deteriorate.

※ Air and water are also impurities in oil.

5) Oil filter

※ When working with hydraulic breaker, the carrier oil filter must fulfill the following specifications;

a. The oil filter must be rated at 25 microns maximum.

b. The oil filter must be a standard return line filter rated to maximum working pressure.
c. The oil filter must have a volume flow capacity at least twice of the breaker's maximum flow.
d. The cooler must withstand a dynamic pressure of 290 psi (20 bar).
e. If the carrier's oil cooler is too small either the original cooler must be replaced with a larger
one or an auxiliary cooler must be installed.

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MAINTENANCE

6) The auxiliary hydraulic cooler can be installed;

a. In front of the radiator, in which case an additional fan is not required, ie. maximum rise of the
cooling air is 5℃(40℉).
b. Any other suitable place, using a fan either hydraulically or electrically driven.

7) Damage caused by hydraulic oil contamination in the carrier and breaker circuits;

a. The working life of the pumps is significantly shortened.

- Premature wear of parts
- Cavitations recommended oil, temperature, viscosity

b. Valves do not function properly.

- Spools bind
- Premature wear of parts
- Blocking of small holes

c. Wear of cylinders and gaskets.

d. Reduced breaker efficiency.

- Premature wear of moving parts and seals
- Danger of piston seizing up
- Oil overheats

e. Shorten working life and reduced efficiency of hydraulic oil.

- Oil overheats
- Oil quality deterioration
- Electrochemical changes in hydraulic oil

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4. LUBRICATION

※ Grease interval
a) Tool shank must be well lubricated before installing tool.
b) 5~10 strokes from grease gun to tool bushing and tool at regular intervals.
c) Adapt interval and amount of grease to decrease wearing of tool and good working
conditions. This should be done every 2 hours.
※ Insufficient greasing or improper grease may cause:
- Abnormal wear of tool bushing and tool
- Tool breakage
※ Technical data:
- NLGI grade 2
- Synthetic oil base with aluminum complex soap
- Approximately 15% graphite copper solids to reduce metal to metal contact damage
- Dropping point 260℃ (500℉)
- Viscosity 15 cSt
- Temperature range -30℃ ~ 230℃ (-20℉ ~ 450℉)

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NOTICE
Grease tool and bushing to prevent economic loss. If the tool is not greased before working,
this can cause accelerated wear of tool bushing and damage or broken tool.

Check grease fitting is not damaged or missing. Replace as required.

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5. CHARGING GAS

5-1. BACK HEAD

1) After installing pressure gauge (25bar) on charging block, turn handle of charging block
anti clockwise.

2) Connect gas hose to N2 gas tank.

3) Install charging block to charging valve on back head after removing plug from breaker.
(Ensure that O-ring is installed on charging block.)

4) Connect the other end of gas hose to charging block.

5) Turn the handle of N2 gas tank anticlockwise to open and slowly turn handle of the
charging block clockwise to set charging pressure.

6) Turn handle of charging block anti clockwise and then turn handle of N2 gas tank clockwise
to close.

7) Close cap of charging block after gas hose is relieved from three of N2 gas tank.

8) Recheck charging pressure into back head as turning handling of charging block clockwise.

9) Disconnect gas hose from charging block.

10) Install charging block on changing valve completely.

11) When turn handle of charging block clockwise, gas pressure in back head is indicated on
pressure gauge.

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WARNING
In charging gas into back head, the gas pressure pushes piston and tool out consequently. Do
not stand in front of the tool during the charging process. Do not charge the back head before
hammer assembly is torqued.
d. Inlet and outlet ports must be plugged to prevent oil spraying.

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SPECIFIED N2 GAS PRESSURE FOR BACK HEAD (25Bar gauge required)

Temperature
B35
(Breaker body)

℃ ℉ bar psi

-20±5 -4±9℉ 8.2 118.9

-10±5 14±9℉ 8.4 121.8

0±5 32±9℉ 8.6 124.7

10±5 50±9℉ 8.8 127.6

20±5 68±9℉ 9.0 130.5

30±5 86±9℉ 9.2 133.4

40±5 104±9℉ 9.4 136.3

SPECIFIED N2 GAS PRESSURE FOR ACCUMULATOR (100bar gauge required)

Temperature
B35
(Breaker body)

℃ ℉ bar psi

-20±5 -4±9℉ 52 754.0

-10±5 14±9℉ 54 783.0

0±5 32±9℉ 56 812.0

10±5 50±9℉ 58 841.0

20±5 68±9℉ 60 870.0

30±5 86±9℉ 62 899.0

40±5 104±9℉ 64 928.0

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5-2. ACCUMULATOR

DANGER
Accumulator is charged with nitrogen gas only. See your CAT dealer for charging kit or charging
process.

INSPECTION OF GAS PRESSURE IN ACCUMULATOR

1. Loosen the Hex. head bolt from the accumulator cover.

2. Remove the Hex. head bolt olt and install gas charging block on it to measure the pressure value.
block, connect the charging hose to N2 gas tank
3. After installing gas charging block tank.

100bar gauge
required

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MAINTENANCE

4. After connecting charging hose, turn the exhaust valve in the N2 gas tank clockwise, and
tighten it securely. And remove the gas charging cap from the gas charging bolt.
5. Turn the gas charging bolt counter clockwise slowly using L wrench.

100bar

6. Measure the pressure inside the accumulator.

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CHARGING GAS IN THE ACCUMULATOR

WARNING
Use Nitrogen gas only.. Nitrogen gas must be used for accumulator and back head.

1. Loosen the Hex. head bolt from the accumulator cover.

2. Remove the Hex. head bolt and install gas charging block on it to measure the pressure value.
tank.
block, connect the charging hose to N2 gas tank
3. After installing gas charging block

100bar gauge

80 required
MAINTENANCE

4. After connecting charging hose, turn the exhaust valve in the gas charging block clockwise,
and tighten it securely.. And remove the gas charging cap from the gas charging bolt.
5. Turn the gas charging bolt counter clockwise slowly using allen wrench.

100bar gauge

6. At this time, the exhaust valve in the gas charging block must be in fully- closed condition.

100bar gauge

7. Slowly open the exhaust valve in the gas charging block, charge the
he gas to the specified value.

100bar gauge

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MAINTENANCE

8. If the pressure is excessively charged over the specified pressure, open the exhaust valve
slowly to discharge the excessive pressure.
9. After charging the specified pr
pressure, turn the gas charging boltt clockwise to close.
10. Remove the gas charging kit from the accumulator and install the Hex. Head
ead bolt again.
11. Install the o-ring
ring into gas charging cap, before installing the cap into gas charging bolt.

12. Check for gas leakage using soap bubbles on the Hex. Head
ead and charging bolt.

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Setting of nitrogen gas pressure

MODEL PRESSURE

B35 60 bar (870 psi)

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6. WEAR LIMIT FOR CONSUMABLES

※ Wear parts
1. When damaged or worn, your attention is highly recommended to exchange these items.
- Tool
- Tool bushing
- Tool pins, hydraulic seals
- Stopper pin, bushing pin, rubber plug, bushing pin plug
- Side bolts
- Hydraulic hoses
2. We recommend the user to stock wearing parts, such as tool pin stopper, rubber plugs, bolts
and hydraulic hoses.

3. Replace hydraulic seals annually or every 600 hours.

4. Tool pin

- When each tool pin is excessively deformed, it is difficult to replace the tool.
- Therefore, every 100 to 150 hours of operation, change the face if each pin which comes in
contact with the tool. The two faces of each pin can be used. If the tool you use is not the
genuine part, we cannot guarantee the breaker parts for their good performance.
- When replacing each part, check each part wear, breakage, scours, etc., especially, after
removing burrs and swelling on tool pins.
- Replace tool
ool after grinding the worn parts of front head and tool pin. Insert a new tool pin
after grinding the scuffed part
parts of front head in use.

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< WEAR LIMIT >

< B35 >

1. UPPER BUSHING 2. UPPER BUSHING PIN 3. TOOL PIN

4. BUSHING PIN 5. TOOL BUSHING

< WEAR LIMIT OF ① UPPER BUSHING >

< UPPER BUSHING >

UNIT : mm
UPPER BUSHING
MODEL
A (New Part) B (Wear limit) C (New Part) D (Wear limit)

B35 101(mm) 104(mm) 153(∅) 159(∅)

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< WEAR LIMIT OF ③TOOL PIN >

< B35 >

UNIT : mm

MODEL E (New Part) F (New Part) G (Wear Limit) H (Wear Limit)

imit) I
1.5
B35 100 50 97 47
(MAX)

※ E, F : Original Dimensions
G,, H : Wear Limit Dimensions

< WEAR LIMIT OF ②, ④BUSHING PIN, ⑤TOOL BUSHING >

< BUSHING PIN >

< TOOL BUSHING >

BUSHING PIN TOOL BUSHING

MODEL
J (New Part)
art) K (Wear Limit) L (New Part) M (Wear Limit)

B35 30(∅) 28(∅) 153(∅) 159(∅)

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7. TORQUE (OPEN TYPE)

HOUSING

6
7

4
1
2
3
8
5

< B35 >

*Numbers show sequence for tightening Housing Joint Nuts.

HOUSING JOINT NUT Ⓐ TOP COVER NUT Ⓑ

MODEL TORQUE TORQUE
(N.m) SPECIFICATION (N.m) SPECIFICATION
1st 2nd 1st 2nd

B35 1,500 3,050 RD52x3.175 1,400 2,800 M36x4.0

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HAMMER

1~6mm

< B35 >

SIDE ROD NUT Ⓐ HEX.SOCKET BOLTⒷ

MODEL TORQUE
(N.m) TORQUE
SPECIFICATION SPECIFICATION
(N.m)
1st 2nd

B35 2,125 4,250 HEX.85x85 200 M14x2.0x40

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VALVE COVER ( UPPER )

VALVE COVER ( LOWER )

< B35 >

VALVE BLOCK VALVE BLOCK

VALVE BLOCK BOLT Ⓐ
COVER BOLT Ⓑ COVER BOLT Ⓒ
MODEL
TORQUE TORQUE TORQUE
SPECIFICATION SPECIFICATION SPECIFICATION
(N.m) (N.m) (N.m)

B35 500 M20x2.5x70 500 M20x1.5x60 500 M20x1.5x45

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< B35 >

ACCUMULATOR ACCUMULATOR
COVER BOLT Ⓐ BOTTOM BOLT Ⓑ
MODEL
TORQUE TORQUE
SPECIFICATION SPECIFICATION
(N.m) (N.m)

B35 550 M20x1.5x60 950 M24x3.0x70

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8. REPAIR & REPLACEMENT

8-1. HOUSING

< B35 >

1) Using the socket bolt (12), fix both sides of set plate (10) and tighten securely.
2) Lay left side of housing (3) down on the supporting block on the flat ground.
3) Place the set plate (11) to the assembling position on the left side of housing. And then, lay
the hammer down on it.
4) Place the set plate (11) to the assembling position on the hammer. After that, lay the right side
of housing (2) down.
5) Install housing joint bolts (4) into housing join nuts and washers (5,6), then insert them from
holes of housing (2) to pass through the holes of housing (3).
6) Tighten the housing joint bolts with nuts and washers (7,8,9).
(Be sure to follow the assembly procedure)
7) After tightening the housing joint bolt securely, stand the hammer up and install top plate with
hex, bolts, washers, and nuts.

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8-2. SIDE ROD

Release the back head gas pressure before loosening side rods.
Otherwise during removal of the side rods, a serious accident could occur.

1) Discharge N2 gas from back head completely before loosening side rods.
2) Remove four side rods, and inspect for any cracks and damages using crack detection dye.

NOTICE
When one side rod is damaged, recommended to replace the opposite side rod.

3) When installing side rods, tighten bolts one turn at a time in diagonal sequence. Use torque
wrench as specified range.

< B35 >

< Loosening and tightening>

Tightening

a. Check the side rod for cracks and replace as required.

b. Clean and grease the threads of the side rods. Apply anti seize on threads.
c. Torque the side rod nuts to specification by the torque wrench.

Loosening

a. Remove the side rod nut and washer.

b. Release the side rod by spanner.

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< B-SERIES >

SIDE ROD NUT (UPPER)

MODEL
SPECIFICATION

B35 HEX.85 x 65

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8-3. SEAL REPLACEMENT

NOTICE

Each seal has different diameter and shape. Check the part list and compare the details (part
name, direction, etc). Be sure to follow the cross-sections of seal housing and lower cylinder.

< B35 >

BACK HEAD LOWER PISTON

SEALING SYSTEM SEALS - CYLINDER

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MAINTENANCE

l MAKE SURE THE ORIENTATION OF SEALS IS CORRECT (AFTER ASSEMBLY)

Check the direction of seals. Each seal has its proper direction. If you assemble them with
opposite direction, oil leakage or malfunction may incur during the operation.

l SEE THE PICTURE OF HAND GRIP (ASSEMBLING METHODS OF SEAL)

Grip the seals so that they form a "U-shape". But do not bend too much or fold them to
prevent the seal from being damaged.

l ASSEMBLE SEALS SECURELY INTO GROOVES

Check if each seal has well seated position. Escape of seal due to the imperfect assembly
can cause the oil leakage.

NOTE

l Grip the seals so that they form a

"U-shape".
l Push the U-shaped seal into the
grooves to be fully seated.

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8-4. PISTON

If the piston has hairline scratch which are visible with the naked eye, the piston can be reused
by polishing.
Polishing job must be done in the clean place, and authorized person only should be allowed to
carry out restoration job in authorized place.

During the breaking operation, tool impact surface of the piston, wear into a concave area.
Measure the deformation, and change the piston if it exceeded allowable wear limit.

- B35 : 1 mm

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8-5. TOOL & TOOL BUSHING

< B35 >

MODEL EYE BOLT “A”

B35 M8 x 1.25P

< FIG 1 >

a. Remove the snap-ring Ⓐ with a long nose plier.

b. Remove the rubber plug Ⓑ and upper bushing pin Ⓒ, which fixed tool pin Ⓓ.
c. Remove the tool pins Ⓓ and pullout the tool Ⓔ.

< FIG 2 >

d. Remove the snap-ring Ⓕ, rubber plug Ⓖ, and bushing pin Ⓗ

e. Pull out the lower tool bushing Ⓘ
f. Remove the socket plug Ⓙ, and upper bushing pin Ⓚ to remove upper bushing Ⓛ.

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1) Assembly of Upper bushing

a. Turn front head upside down.

b.. Insert the upper bushing into the front head
head.
c.. Put the puller and cylinder on top of upper
bushing.
d.. Insert the shaft into the front head tap hole
and tighten it again.
e.. Operate the hand pump, and assemble th the
upper bushing,

Note
eating up of upper bushing area to 100
Heating
degrees Celsius may be required for assembly
of upper bushing.

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2) Disassembly of Upper bushing

a.. Stand front head upright, and insert the

puller.
b. Put the cylinder on the top of puller.
c.. Assemble Washer & Nuts to the shaft, and
then assemble it with the support plate.
d. Fix the shaft to the front head and tighten it
with Lower nuts.
e.. Operate the hand pump continuously to push
bushing fall
the puller down until the upper bush
down to the ground.

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9. DISASSEMBLE THE HAMMER POWERCELL

1. Lay hammer down with accumulator

facing up on the thick board.

2. Push the hole at the charging valve by

pin, and release nitrogen gas
completely.

DANGER
Before disassembling breaker, all remaining gas should be discharged completely from back head.
Otherwise, it could result in serious injury or death.

CAUTION
Wear goggle to protect eyes from discharging gas or dust emission. Don't be too close to the
emission valve.

a. Remove the snap ring 1) with a long nose plier.

b. Remove the rubber plug and upper bushing pin 2),
which fixed tool pins.
c. Remove the tool pins 3) and pullout the tool 4).

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MAINTENANCE

Remove the snap ring, rubber plug, and bushing pin.

And then pull out lower tool bushing, upper bushing.

Remove the accumulator from the power cell. Keep

in mind that the cylinder contact side of accumulator
must be cleaned and not damaged.
Refer to the page on 109.
"ASSEMBLING PROCEDURE OF ACCUMULATOR”

CAUTION
Do not disassemble accumulator without releasing
nitrogen gas.

Remove the valve block sub assembly from the

power cell.
Keep the valve block assembly in the clean place not
to enter the dirt or dust.

Loosen the side rod nut with ring wrench. Before

standing up the power cell, retighten the side rod
nut by hand to prevent the inner parts from being
damaged.

CAUTION
Back head nitrogen charge MUST be released
before removing side rods.

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MAINTENANCE

Stand the power cell vertically using eye bolts.

Secure hammer in stand for safety.

Loosen and remove the side rod nuts & washers, and
install lifting eye bolts into back head.

Disassemble the back head with crane.

WARNING
Be sure to use a crane to handle or move the heavy parts.

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Loosen the side rod bolts with spanner. Check the

threads for damage or cracks.

Note
Use dye check for detecting cracks

During loosening side rod bolts, slightly hit the side

rod lower nuts with a mallet for easy loosening.

Install the eye bolt on the lifting point of piston and

pull out the piston slowly. When you pull the piston
out, seal housing will come up. To remove seal
housing from piston, tap with rubber hammer.

NOTICE

Always you must pay attention to handle the core parts like piston, cylinder, seal housing valve
block. Be careful to use rubber hammer if necessary, but do not damage the core parts.

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Pull out the piston slowly.

Remove the cylinder from front head.

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9-1. ASSEMBLING PROCEDURE OF ACCUMULATOR

DANGER
Discharge high pressure accumulator before disassembling.

of the
1. First, prepare the accumulator inner valve. Then, assemble inner valve in the middle o
accumulator bottom cover.

2. Tighten the inner valve Hex. nut on the cylinder contact side, and then tap with handy chisel
between inner valve thread and the Hex. nut to prevent from loosening.

3. Cover with silicon grease (that contains Teflon) on membrane gas side and accumulator cover
inside, and then install membrane correctly.

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4. Assemble the accumulator cover

over to bottom using twelve Hex socket bolts with anti seizes.

5. Tighten the accumulator bolts in a diagonal sequence as shown in “View A””.

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6. Install O-ring
ring into the gas charging valve, and install into the ac
accumulator
cumulator cover after greasing.

7. Install O-ring
ring into the Hex. bolt
bolt, and install into the accumulator
cumulator cover after greasing.

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10. ADJUSTMENT

10-1. CYLINDER ADJUSTER

The cylinder adjuster is standard on all “B-series” models and provides the option of regulating
the blow frequency. For the most effective breaking, ch
change
ange the number of blows depend
depends on
the working condition:

l The adjuster is located on the right side of the cylinder (as viewed from operators cab)
l Piston
iston stroke and frequency can be changed to keep working pressure ure and flow rate constant.
l Factory setting is long stroke position.(fully tightened)
l To change the adjuster, rotate the adjusting bolt counter clockwise by allen wrench
wrench.
l For maximum frequency, adjust the bolts by rotating counter clockwise two turns.
nut.
After adjustment, retighten the nut

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10-2. VALVE ADJUSTER

B-SERIES hydraulic breaker has an adjuster valve which controls the oil flow to tank from upper
piston shoulder area.

CAUTION
DO NOT close the adjuster completely as this creates a hydraulic lock and hammer will not run.

Adjuster is set 2.5 turns open from factory and does not need to be adjusted for Caterpillar
carriers.

CAUTION
DO NOT exceed a maximum of 4 turns open.

Adjustment option – Non-Cat machines for adjusting operating pressure to hammer

specifications.

CAUTION
Do not exceed, the seals of inner hammer could have damage, so that damage of seal may result
in oil leakage.

SETTING INITIAL STATUS OF ADJUST BOLTS

1. Loosen the adjust nut to enable the valve-adjuster to be turn.

2. Turn the adjust bolt clockwise, and tighten it securely.

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MAINTENANCE

3. Turn the adjusting bolt 2.5 turns counter clock wise.

4. After completing adjustment, hold the bolt and tighten the adjust nut.
5. After finishing the adjustment, ttighten the adjust nut securely.

SPECIFIED ADJUSTMENT OF VALVE

NUMBER OF
MODEL
TURNS OPEN

B35 2.5 rotation

< FIG 1 >

NOTICE

1. The adjustment of this valve adjuster is needed only when the oil flow and the operating
pressure are less than the required specification value. Otherwise, do
o not adjust.
2. The valve adjuster is set at the position of 2.5 times counterclockwise turning when first
factory.
released to the customer from factory
counterclockwise.
3. DO NOT turn the valve adjuster more than 4 times counterclockwise

110
TOOL FAILURE
ANALYSIS

111
TOOL FAILURE ANALYSIS

1. GUIDELINE FOR VARIOUS TOOL FAILURES

CAT hydraulic breaker tools are made from top quality grade steel, heat treated, machined, and
inspected for maximum consistency and reliability.
Breaker tools are consumable parts, used under severe conditions.
Breaker tool failures result from various conditions, maintenance, grease interval/type, application,
tool selection, and operator experience.

In general, the tool can withstand vertical hammering, if the tool is bent, twisted or blank firing is
performed, tool failure can happen. When operating more than 15 seconds in one spot without
tool penetrating, the tool will overheat causing mushrooming of the tip.

112
TOOL FAILURE ANALYSIS

TOOL TROUBLESHOOTING

Failure dented by imperfect blow due to

NOT WARRANTY
excessive wear of tool bushing
bushing.

Failure due to blank firing or heavy wear

NOT WARRANTY
of tool pin groove.

Failure due to excessive bending,

seizing in tool bushing, prying heavy NOT WARRANTY
objects (Typical failure
failure)

Mushrooming of fast wear of tool tip

caused by blowing on the same spot at
NOT WARRANTY
a time for a long time, levering, and
improper firing
firing.

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TOOL FAILURE ANALYSIS

1-1. TOOL FAILURE ACCEPTED UNDER GOODWILL

MATERIAL FAULT

Fatigue failure is started from the inside of breaker tool. This is the only kind of failure pattern
that is always acceptable for goodwill coverage.

INTERNAL MATERIAL FLAW

INTERNAL MATERIAL FLAW

INTERNAL MATERIAL FLAW

114
TOOL FAILURE ANALYSIS

1-2. TOOL FAILURE REJECTED UNDER WARRANTY

1) FATIGUE FAILURE (NOT WARRANTY

WARRANTY)
This pattern is typical failure caused by prying
prying, levering.

a. Fatigue starts from "X" called "Stress Raiser"

b. Size of "Y" area is dependent on how far fatigue has progressed through section before check
all hammer parts and either replace
eplace or repair damaged parts.

115
TOOL FAILURE ANALYSIS

2) EXCESSIVE BENDING (NOT WARRANTY

WARRANTY)

Bending stress exceeds material strength causing tools to snap off. It is caused by wrong
working angle or use of tool for mechanical leverage. Failure generally occurs near front face of
tool bushing. Failure type is brittle fracture with a typical lip fo
formation.

116
TOOL FAILURE ANALYSIS

3) SEIZING IN TOOL BUSHING (NOT

NOT WARRANTY)

Strong side load and striking at the same time can cause damage tool and tool bushing surface
surface.
This pattern is caused by wrong working angle, wrong or insufficient lubrication or both.
Failure generally occurs in front tool bushing area.

117
TOOL FAILURE ANALYSIS

4) OVERHEATING (NOT WARRANTY)

Overheating of tool due to driving the tool end into hard dense material for too long period of
time without penetration will incur fast wear in tool end. The overheating will soften the tool end
causing it to mushroom and peel.

5) BREAKING OR FAST WEAR OF TOOL TIP (NOT WARRANTY)

This pattern is caused by levering or hammering obliquely (not vertically)

118
TOOL FAILURE ANALYSIS

6) BLANK FIRING (NOT WARRANTY)

Blank firing will incur heavy wear on tool retainer groove. It may cause the serious wear or
damage at tool pin groove area. Therefore, tool pin also could be often cracked, even broken.

119
 WARRANTY

Coverage CAT WORK TOOLS WARRANTY

Worldwide
SELF5453

NOTE

Hammer must be SCORED by dealer for warranty

120