SOOSAN HYDRAULIC BREAKER tiated MANUAL ey NSE tod A DANGER + SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR ve Soilonemniy a + REPAIRS AND / OR SERVICE TO THIS BREAKER MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER. wu E SS > SOOSAN/\ DANGER © DO NOT OPERATE THE BREAKER UNLESS THE FOLLOWING SAFETY INSTRUCTIONS HAVE BEEN THOROUGHLY READ AND UNDERSTOOD! READ THIS MANUAL BEFORE INSTALLING. OPERATING OR MAINTAINING THIS EQUIPMENT. @ Flying debris from the breaker, breaker rod, rock or other materials may cause serious or fatal injury to bystanders. Never operate the breaker when bystanders are in the work area. @ On some machines/carriers, the breaker can enter the operator's compartment if it breaks loose and swings toward the operator. Make sure that suitable impact shields are used when operating the breaker with this type of equipment @ Do not operate the breaker unless all safety decals described in this manual are in place. The decals must be inspected periodically to ensure that all wording is legible. The decals must be replaced if illegible. Replacement decals can be obtained from your authorized Soosan Distributor. @ When operating the breaker ear,eye and breathing protection must be used at all times @ The breaker will become very hot during operation. Allow time for breaker to cool down before touching breaker parts SOOSAN C03 296PREFACE We appreciate your purchasing a Soosan Hydraulic Breaker. The hydraulic. breaker designed and built to provide durable operation under any working conditions, has been developed by Soosan's excellent engineering techni ques with accumulated experiences for many years. Without proper hand ling, regular inspection and maintenance, however, the machine fails to display its full capacity, resulting in various troubles of machine parts. This publication should be carefully read prior to installation and operation in order to prevent any mishandling of breaker. We guarantee that a faithful compliance of the instruction will contribute to the best operation condition Customers are, therefore, required to keep in mind that the company is not responsible for troubles caused by not following our guidelines or not using genuine parts. Soosan Heavy Industries Co., LtdSOOSAN HYDRAULIC BREAKER OPERATION MANUAL SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERIVICE OF THIS BREAKER REPAIRS AND / OR SERVICE TO THIS BREAKER MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER. Model Serial Number Year of ConstructionEC declaration of conformity according to EC Machinery Directive 98/37/EC We herewith declare. SOOSAN HEAVY INDUSTRIES CO., LTD 109-2, Songsan-Ri, Yanggam-Myeon, Hwaseong-Gun, Gyunggi-Do, Korea that the following described machine/machinery part in our delivered version is to be incorporated into a(n). machinefassembly with other machinery to build one machine and that the machinery shall not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the EC Machinery Directive 98/37/EC. Description of the Machine/Machinery part Hydraulic Breaker Possible Machine type SB10, 20, 30, 35, 40, 43, 45, 50, 60, 70, 81, 100, 121, 130, 140, 151 Possible Serial Number Possible application Harmonized Standards ; £N292-1 : 1991 EN292-2 / A1 : 1995 EN414 : 2000 EN954-1 : 1996 prEN 13778 : 1999 EN 982 :1996 Notified Body according to annex Vil TUv Product Service (name, address) Responsible for = EC type-examination (EC type-examination certificate no, 8 02 08 26208 017) WZ : Date/authorized Signature: 7 Rass 9 Title of signatory: Director Archives Mach-NoSurpiooay 1onpod @ Asn Lavd @ (vondo) s8¥281g 841 Jo UoNEI8d JAIeMapUN SL = (uondo) 14 voneouan|ony euL PL HO oUNeIPAH EL weyp Buyooug aiano.y 24 = JojeInwNaDY Je SEO %\ BulBseYD PUB UIO}DedsUy | peaH YONG Te SED AN OulbseUD pUE Ulo}oedsuL — aouesjo| 129M uonsadsuy pue seday seyeeig] ONeIPAH ey) JO feAoWeY PUB LONE|/EISUI — Jayeaig o1INEIpAH ayy BuNeIEdQ suonneaaig uoneiadg €8sn anisnjoxe J0} seul adic OuNeIPAH €"y — yeyoelg do} pue jayowsgapls uoRe|eIsul 2"y = “suononysu! UOWEHEISU! 810499 ¥98UD L'y a — uojerede pue uorye}ie}su 10} uoNeIedaid BLV1d HBAOD ee = AdAL d-SLz'e 3dAL dOL 9 30IS Le Suojsuawig jeuIEeKg \- uoneayloodg prepurig z (e176 oneoig ay) Uo a9eid pue ISI FNS ZL — suonnesaid Aayeg 44 — suoyneoaid AyaIeg | TWANWW NOILVHAdO @ SLN3.LNOOHYDRAULIC BREAKER OPERATION MANUAL 1. Safety Precautions 1.1 Safety Precautions IM This manual contains safety, operation, and routine maintenance instructions. It doesn't contain service disassembly and service assembly instructions. If needed, complete service disassembly and service assembly instructions are contained in manual which can be ordered from your Soosan Hydraulic Breaker authorized and certified dealer IH Picase read the folowing warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS BREAKER. REPAIRS AND / OR SERVICE TO THIS BREAK ER MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER. GENEARAL SAFETY PRECAUTIONS WM The Soosan Hydraulic Breaker Serise SB Type will provide safe and dependable service it operated in accordance with the instructions given in this manual, Read and understand this manual, any decals and tags attached to the breaker before operation. Failure to do so could result in personal injury or equipment damage. @ Operate the breaker in accordance with all laws and regulations which affect you, your equipment. and the worksite © Do not operate the breaker until you have read this manual and throughly understood all safety, operation and maintenance instructions © Do not operate the breaker unt you have read the carrier equipment manual and throughly understood backhoe or excavator or similiar equipment used to operate the breaker. The word "carrier", as used in this manual, means a backhoe of excavator or similar equipment used to operate the breaker @ Ensure that all maintenance procedures recommended in this manual are completed before using the equipment © The operator must not operate the breaker of cartier if any people are within the area where they may be injured by flying debries or movement of the equipment. © Know the limits of your equipment. @ Establish a training program tor all operators to ensure safe operation. ® Do not operate the breaker unless throughly trained or under the supervision of an instructor. © Become familiar with the carrier controls before operating carrier and breaker. @ While learning operate the breaker and carrier, do so at a slow pace. If necessary, set the carrier mode selector to the slow position. ® Make sure all controls(levers and pedals) are in the neutral position before starting the carrier. © Before leaving the carrier, always lower the boom and insure the carrier is stable, Never leave the machine with the engine running. Always engage the parking brake. @ Stop the engine before attempting to make any repairs, adjustmants or servicing to either the arian ar the hraaker@ Do not operate the breaker at oil temperature above 175°F /80°C. Operation at higher temperature can damage the internat components of the breaker and carrier and will resull in reduced breaker Performance © Do not operate a damaged, leaking, improperly adjusted, or incompletely assembled breaker. ® Do not modify this breaker in any manner. ® Use only breaker rod manufactured by Soosan. Usage of breaker rod produced by another manufacturer may damage the breaker and will void the warranty, © To avoid personal injury or equipment damage, all beraker repair, maintenance and service must only be performed by authorized and properly trained persornel @ I you do not understand how to operate safely your breaker, contact an authorized Soosan Dealer for assistance. © Keep this manual with the breaker. © Do not operate this equipment if you are taking medication which may affect your mertal judgement or physical performance. ® Do not operate this equipment if you are under the influence of druges or alcohol. ® Remove breaker from catrier during transportation,HYDRAULIC BREAKER OPERATION MANUAL 1-3 Warning Sticker (C03192) = shown smaller actual size OO ® Read Wear ar Wear Manual Breathing Protection Ear Protection Eye Protects @ Safety Symbols _AXDAN ZNWARNING IMPORTANT This symbol indicates an This symbol indicates a This sigan! word indicates @ imminently hazardous situation | potentaly hazardous situation | situation which, it not avoided which, if not avoided, wil witich, if ot avoided, could — | may resut in damage to the result in death or serious result in death or setious equipment injury ininy @ Satety symbols are to emphasize all operation, maintenance and repair which, jf not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment @ Always observe safety symbols. They are included for your safety and for the protection of the tool I Greasing Sticker (083168) GREASING 1. With breaker mounted on cartier, apply down pressure on rod. 2. Fill cavity with recommended grease through the grease fitting 3. Grease whenever rod looks dry. 4. When installing a new rod, liberally coat the upper 1/S of the rod with grease before inserting. 5, Failure to comply with these instructions can result in damage to the breaker and will void the warranty.M Local Safety Regulations Enter any local safety regulations hear. Keep these instrutions in an area accessible to the operator and maintenance personnel MM Breaker Sticker and Tags Stickers and decals placed on the breaker at time of manufacture are shown to the right and decals have been placed on the breaker to aid the operator with safety and general maintenance. The information listed on these stickers and decals must be legible at all times. Always replace any sticker or decal that has become worn or damaged Replacements are available from your Soosan Distributor. @ Specification Plate (For Exemple $8130) OS] c€ SOOSAN HYDRAULIC BREAKER MANUFACTURED BY : SOOSAN HEAVY INDUSTRES C0, LTD 51-1 Bongyee-Deng. Songpa-Gu, Seoul, Korea Serial No Operating Weight “Operation — 200-260 ‘ot copacity | _50.8-66.7 ‘Operation 160-180 — ka/er# Perot eressure | 2298p AM Date of constructionHYDRAULIC BREAKER OPERATION MANUAL 1.2 Sticker List & Placed on Breaker (SB10~SB70) No sticker |} Danger | waming | Spec | BackHead | Greasing NAME | Sticker | Sticker Plate Sticker | Sticker seio | esoia7 | eesiae | cestas | ceataa | coarse | esaias se20 | costes | costse | Fosi23 | coatss | coatss | Fostta seao | costes | costs2 | evs130 | coatas | co2tss | evsiza seas | costss | costse | Fesiso | co2tss | coatss | resist seso | cosiss | cosisz | cosscr | cozias | coziss | costts seas | cosiss | cosise | Fesis7 | coatas | cozise | Fastes sess | cosies | costse | paszeo | coates | coziss | vasita seso | cozies | costse | cissee | coatss | co2iss | cosite seco} coziss | costse | casass | coatss | coarse | casita p70 | coszee | estes | tosiso | coatss | coztas | Lostas mf (a) fat E d | \ © MAIN RANVel 1.3 Sticker List & Placed on Breaker (SB81~SB151) No 7 2 3 @ 5 é 7 a STICKER || Danger | Warning} Spec | Acc Ace’ | BK | Groasina| Model NAME | Sticker | Sticker | Plate | Sticker(B)] Sticker(B)] gicye, | Sticker | Sticker Bai | cozisa | cos192 | ca3450 | ceza12 | ce22i3 | co2i3s | co2t36 | ca2248| seio0 || 083167 | 083166 | E93190 | cez2t2 | c62213 | coziss | pastes | E93138 sa121 || co2ziss | cost92 | ce3254 | ca2212 | ce2213 | co2t35 | coz136 | cez2a5 sa130 || coztss | cosi92 | pesza1 | cezzt2 | ce2213 | cozt35 | coztze | pa2115 s8151 || coat9s | coarg2 | c7st67 | cez212 | c62213 | co2135 | coz1a6 | c73130 LEFT MAIN BODY RIGHTHYDRAULIC BREAKER OPERATION MANUAL 1-7 Placed on Breaker (SB10TS-P~SB151TS-P) 1.4 StickerAL CRE ACE RR RSE TED AAR A 2. Standard Specification (1/2) MODEL SECTION UNI saso | seas | saa | seas | sass | saso Body |inctuding] ko | 59 | 65 | a8 | 122 | ts [ ae | ave | an Weiant | Rod [ip [riz [14a | 190 | 260 ee ae xo | 70 | 9% | 120 | 100 | a | ovo to [164 [198 [265 [307 | ss | ese | 1124 | t687 ro | 73 [| too | 120 | te | 202 | are | arr | avo ib | tr | 220 | 205 | «17 | osr | 27 | 1272 | 1002 to] 102 [128 za_| 20s | ars | or | an TSP | 2s | 278 aoa | oso [eer [1250 | i00 side [mm | ove | 1000 | 110 | 1208 | vas | roo | iver | 1000 Tye [in [383 | goa | eto [ser we | se | 7a op Twpe| mm | tora | ine | v2a0 | rae iia] 20a | 2261 Length awenoa| in | «22 | aer | 40 | see | a1 | o77 | a26 | a0 tsp [mm [ies [vase [tee [sare | so00 [tase | 2io1 | axze in [a7 [aor [sea [s80 [exo | 72 | a7 side | mm | ise | v6 | ivr | os | 2a | a0 | oor Te [Tin [ee [ee [70 [es [es Poa Pat Hop Type] mm | tee | ize | ivr | 20s | aso | coo | os? | 38 Wicths a torencr |""in [64 | 69 | 70 | 93 | 138 | ive | van | ave yoo Lm || seo | 06 | are | «20 in | e9 | t04 ize | 132 | as | tes imin | 18-20 | 20-4 0-70 | 50~ =100 | a0- ae Ynin | 18-80 | 20-40 «0-70 | 0-20 | 60-100 | a0~110 Gil Flow renee lees alee ig [tea [ait lcaymin| 4-8 |5.2-106]6.6-12.2| 7.9~16 ee 100-160] 110-140] 120-750] 190~v60] 160-17 fe 0-160] 110-140] 120-750] 190-v60] 160-170 Pressure fi 14a | 1865 [1707 | ieea | 2136 ps ~1940 | 1001 | 213 | ~zere | -2a18 jaeise | 2 Impact Rate | BPW 800 | §00~-200] a00-200| «00~800] 350700 ~1000 Hose Diameter i (ean + + $ ¢ mm co | eo | 7 | es Rod Diameter in| 16 [ie [en [ee [ar [ae [oes tt jo wt _ [ooreie[o.0s-0.1]0.06-02[0.1-025]0.15-0.8[0.2-0.25[0 25-05] Applicable Carr ao-ss|ao-70| 6-9 | 7-14 Noise Level 1 awa | 1255 | 1088 | toss | 169 | 1007 | tas | se | 1195 © Operating Weight include Cap,Red weight by AEM regulation, (xce0t fr pin, hose, fiting ard tubing) © The above specifications are cubjct to change without rior natice forth auaiy enhancement © The above Noise Level is TS-P tyne. © Rodis long type standHYDRAULIC BREAKER OPERATION MANUAL 2-2 Ce a 2. Standard Specification (2/2) SECTION UNIT seo | B70 | sast sBi5t Body |inctusing] ko | ore | 79 | on | w072 vaca 1579 | 1920 weiant | Rod |" to | tase | 1673 | 2008 | aes aii | 3081 | aeue site | Ko | 1255 | 1462 | 17a | araa | ama | 2650 | 2900 | 3768 Type [in aver” [3320 aea6 [azar saa0” | aeae | es00” | east Operating |Top Type] ka | 1903 | vere | asa | ore | 255s | aos | - Weight | crrencwn | ib” [2673 [3340 agar | 569 | érar ka_| 1297 | 1600 zor | 2632 | 2033 | 2090 TSP ib side | mm Type [in Top Type] mm natn |"? TYP arevcin [in [982 [toss [aint | i200 a2 aoe sp [me pei | 2ace | s0se 3303 | 3461 | 3700 : in 1os9 | 111.9 | 1202 | 1281 | i936 | 1363 | 1460 sido | mm | soe | soe | soa | 00 | co | ow | cx | cas Type | in | 200 | 200 | 200 bao | 20 [one Top type] _mm | 496 | se0 | 620 | ea | m0 | mo | - width caencni[” in | 196 | 226 | 244 | 264 [ 280 | 260 | - mm | se | seo | 620 | eo | v0 | 70 | 730 (1s-P) in | te [228 | aaa | 26 | 280 | 280 | 287 | 209 Reauived ‘min | 90-120 | 100~150] 120-180] 160-210] 180-240] 200~260| 200-260 | 210-200] Oil Flow yma 28 | 268 [sir [aoe [Ware [toe [soe | cs joavmin| air | ~396 | ~a7.6 | -55.5 | -c34 | -037 | ~68.7 | ~76.6 to/ae | 160-170] v60-180] 160-120] 160~160] 160-180] 150-180] 160-180] 160-180 Operating Pressure bisa | 2076 | zare | 2276 | 2076 | 2270 | 2276 | 2276 psi_| “aare | ~2s60 | ~2560 | -2560 | -20e0 | ~25e0 ] ~2560 | ~2560 Bem | 350~650| 350~600] 250~sa0] so0~ 450| s00~a50] 250~ 400] 250~350] 200 ~a60] Impact Rate Hose Diameter 1 o 1h it mm | 12 | 135 | 140 | 150 | 155 | 155 | 165 Fod Diameter in [se [ss [ss | se | 61 | 6: [ 65 | 69 w 09-12 Applicable cartier ton y ea ' Noise Level wa) | 20 {© Operating Weight inch Cap Rad weight by AEM regulation (Exceet for pn, noe iting and tubing) © The above specifications are subject to change without pie not forthe quality an (© The above Noise Levels TS-P typeSRNAL DIMENSION 3.1 SIDE.& TOP TYPE MODEL : SB10 SIDE TYPE TOP TYPE 10723dAL dOL BdAL 30S 02aS : 1300N ze MNWWNOWEO aS OINVECAPBdAL dOL 3dAL 30IS eas : 1300N aNvaua OMiMvacAr TWANVIN NOUWEO €-£HYDRAULIC BREAKER OPERATION MANUAL 3-4 a MODEL : SB35 SIDE TYPE | | | eo | | v TOP TYPE 295 by oI. pag 1pMODEL : SB40 SIDE TYPE TOP TYPEOPERATION MANUAL 3-6 HYDRAULIC BREAKER MODEL : SB43 SIDE TYPE d = ==> 7+ See ne fe Sa a | TOP TYPEMODEL : SB45 SIDE TYPE TOP TYPE =<] |HYDRAULIC BREAKER MODEL : SB50 ‘SIDE TYPE 1017.5 Beil (( o oO 1978 TOP TYPE OPERATION MANUAL 3-8MODEL : SB60 SIDE TYPE TRENCH TYPE 98 rE ri I Mo A 3 NEHYDRAULIC BREAKER MODEL : SB70 SIDE TYPE 2289) TRENCH TYPE 1677 OPERATION MANUAL 3-10 9195 + 2325,MODEL : SB81 SIDE TYPE TRENCH TYPE _| as ——2 1694 2350 eT & <=—fEEI ®HYDRAULIC BREAKER OPERATION MANUAL 3-12 MODEL : SB100 SIDE TYPE 590 | i a ag bo e150 TRENCH TYPE 620 a ojo ofo | a |MODEL : SB121 SIDE TYPE (as ie —— ee BEST Li ‘9Ise TSS ST al 6 ct | rs TRENCH TYPEHYDRAULIC BREAKER MODEL : SB130 SIDE TYPE TRENCH TYPE 14nsa4as.s) BEGET. OPERATION MANUAL 3-14 6101630) no aissco1es) no | 2705 _2308 <= [Sesl 2elMODEL: SB140 SIDE TYPE TRENCH TYPEHYDRAULIC BREAKER OPERATION MANUAL 3-16 | MODEL : SB151 SIDE TYPE id | bd [| xs | 0 TRENCH TYPE 2363 30973.2 TS-P TYPE MODEL : SB10TS-P~ SB35TS-P 282 — = Wb, at PS] O- us ZZ aS | = | eo 6 (P88 ° E g ws SB20TS-P a ‘ cs =] | 053 SBSOTS-P 00 960 SBSSTSPHYDRAULIC SREAKER OPERATION MANUAL 3-18 MODEL : SB40TS-P~ SB45TS-P 320 to. |= = | 09 ila i e lS] || 6 213. 228 SOMOS. SB4STS-P feel | iS 6) Re | ceo asd 985 | SBOSTS-PMODEL : SB50TS-P~ S881TS-P SBOOTS-P SBSOTS-P i Va a SBSTTS-P SBYOTS-PHYDRAULIC BREAKER MODEL : SB100TS-P~ SB151TS-P OPERATION MANUAL 3-20 3058 1920 2780) mm Yay I ye wag a Pata oH eo ala oan — Lowlé 2 2 | r— | : Bla 5 2 | |8 — oro oy °3.3 COVER PLATE (TS-P Type) ~ $810~30TS-P Model SB10TS-P 14 | 266 252[ 70 | 70 | 70 | 28 | 20 | a12| 17 ‘SB20TS-P 14 _ | 280 204 74 | 74 | 74 [ 29 | 20 | 224] 19 S830TS-P 204| 74 | 74 | 74 | 29 [ 20 | 224] 19 - $835~43TS-P Model Thickness SB35TS-P 19 ‘SB40TS-P 19 | 400 SB43TS-P 19 [450 336HYDRAULIC BREAKER OPERATION MANUAL 3-22 = SB45~151TS-P Model | Thickness] A | B | C H vfK ‘SB45TS-P. 9 | 495] 378 | 149 | 149] 149[ 24 | 24 | 100 | 130 ‘$B50TS-P 19 | 570] 420| 170] 180] 170] 25 | 25 | 120 | 130 SB60TS-P 22 | 640 | 498 | 180| 190] 180] 45 | 45 | 122 | 164 SB70TS-P 22 | 660| 580 | 180 | 210| io | 45 | 50 | 150 | 180 SB81TS-P. 22 | 700 | 620 | 210 | 210 | 210] 35 | so | 160] 200 ‘SB100TS-P 22 | 760 | 620 | 225 | 240 | 225] 35 | 35 | 175 | 200 geieits-p | 32__| 820| 710 | 245 | 250 | 245 | 40 | 40 | 200 | 230 $B130TS-P 32 | 820 | 710 | 245 | 250 | 245 | 40 | 40 | 200 | 230 s8140TS-P 32 | 832 | 730 | 251 | 250 | 251] 40 | ao _| 210 | 230 BiSiTs 896 | 760 | 258 | 260 [ 268 | 60 | 60 | 220 | 2004. Preparation for Installation and Operation 4.1 Checking before installation i ZX WARNING ‘SEE THE "SPECIFICATIONS’ SECTION OF THIS MANUAL TO DETERMINE CORRECT EXCAVATOR SIZES AND HYDRAULIC FLOW AND PRESSURE REQUIREMENTS, IF HYDRAULIC PRESSURE, HYDRAULIC FLOW OR EXCAVATOR WEIGHT CLASS ARE EXCEEDED, THE BREAKER WARRANTY IS VOID IMPORTANT BE SURE THE FLUID IN THE HYDRAULIC SYSTEM IS CLEAN. CHECK THE HYDRAULIC FILTER. REPLACE THE FILTER IF DIRTY OR DETERIORATED. CHECK THE GAS PRESSURE ACCUMULATOR AND BACK HEAD. ‘SEE INSPECTION AND CHARGING OF NITROGEN GAS AT BACK HEAD, ACCUMULATOR HOSE AND PIPING FLEXING. IMPORTANT THE CONTAMINATED PART MUST BE CLEANED WITH NO DELAY. HYDRAULIC Ol OR LIGHT OIL IS HIGHLY RECOMMENDABLE, IMPORTANT THE CIRCUIT RELIEF SETTING PRESSURE IS NOT FIXED. BUT, IT WILL BE ADJUSTED BY PUMP CAPACITY. Recommended circuit relief setting pressure and back pressure MODEL 8810 | $820 | sso | se sp40| seas | sas] sa50] REMARK Relief Sett Pressureligiee) | 152 | 150 | 160 | 160 | 170 | 180 | 190 | 200 Back Pressure fee 10 |? 10)2| 7-10: |e 10le|- 10: || 10H 107} 110) MODEL 8860 | $870 | sB81 |sB100]sB121|sB190]sB140]sB151] REMARK Relief Setting oot pressurelkg/ar) | 200 210 y2to | 210 | 210 | 210 | ato | 210 Back Pressure Tkg/ew) io | 10 | 10 | 10 | 10 | 10 | 10 | 10 @ Since Soosan's hydraulic breaker operates with various kinds of hydraulic construction machines, it should be installed after our serviceman's check of carrier to display its full performance. Necessary preparations prior to installation and operation of the hydraulic breaker are following ————HYDRAULIC BREAKER OPERATION MANUAL _4-2 4.2 Installation side bracket and top bracket WW Side Bracket Type High-pressize line | ~ Breaker body Foot pedal I Top Bracket Type & Trench Type. ‘op bracket4.3 Hydraulic pipe lines for exclusive use. Operation of the hydraulic breaker requires installation of hydraulic pipe lines for exclusive use of the hydraulic breaker. As hydraulic pipe lines vary depending on base machines, our service engineer must first check hydraulic pressure, oil capa city, pressure loss and other conditions of the base machine before installing hyd raulic pipe lines. Use only genuine parts in case of replacement because hydraulic Pipe lines(hoses, pipes and fittings) are made of materials carefully selected in consideration af durability. THE HYDRAULIC SYSTEM TO THE BASE MACHINE MUST BE CHECKED BY AN AUTHORIZED SOOSAN SERVICE ENGINEER BEFORE FIRST USE AND AFTER ANY MODIFICATIONS. JM MAKE SURE THAT THE BREAKER VALVE OF HYDRAULIC SYSTEM IS PROPERLY SET. RELIEF VV! > i i STOP VV IN PILOT Viv on [ : O/SWITCH ee GEAR PUMP MAIN PUMPHYDRAU. BREAKER OPERATION MANUAL _ 5: 5. Operation Precautions IMPORTANT Apply down force to the boom/dipper until the front of the cartier is arised off the ground. The breaker is more efficient when adequate down force is applied Do not break continuously in one place ~ Continuous penetration in the same area for lenathly period will create & sssive temperatures. at the tip of rod resulting in loss of temper(hardness) of the rod and causing mushrooming of the tip of the rod, And may lead to failure of the rod WW Do not pry with the rod and breaker Prying will damage the rod and associated breaker components, The contaminated parts must be cleaned with no delay. = Hydraulic oil or light oil is highly recommendable Avoid blank hammering ~ Blank hammering accelerates wear and tear on breaker and carrier components and may result in failure of one or more components. Excessive blank hammering may be considered equipment abuse and may result in voiding warrantie MM Break a large rock from edge. Do not do breaking operation at the stroke end of the carrier cylinder = Breaking operation conducted at the stroke end (when the cylinder is extended or retracted to spective hydraulic cylinders of a carrier will lead to damage to the a maximum extent) of 1 cylinders and other parts of the carrier6. Operating the Breaker @ Proper position must be applied for an effective usage of breaking force. When Position js incorrect, hammering energy of the piston is too weak to break rocks. Instead, hammering force applies shocks to the breaker body, breaker, arm and boom of the base machine, thereby resulting in damage to those parts. EG A B= — WY - eo =x) O ———*) == 9 9) @ On the contrary, when position is excessive enough to break rocks with front of the base machine raised, the machine may suddenly tilt forward the moment rocks are broken. Then, the breaker body or the end of bracket may violently hit against rocks and result in damage.HYDRAULIC BREAKER ‘OPERATION MANUAL 6: It is undesirable to carry out hammering under the below condition, because vibrations during hammering may be transmitted to tracks of the base machine During hammering, however, proper position must be always applied to the breaker Special care must be taken not to hammer under abnormal condition a> q~ ne NU4 Q © Apply same direction of boom force in line with the rod and place the rod in the rock with hammering surface as vertical as possible. If hammering surface is oblique, the rod may slip during hammering. This causes the rod to seize and to be broken and piston to be damaged. When breaking, fully stabilize the rod first and then select the point of a rock on which hammering can be performed in a stable condition.Do not move rock. Rolling or falling a rock with the rod end or bracket side by using the boom or arm of the carrier as shown in the figure will result in breakage of the breaker mounting bolt or bracket, breakage and galling of rod, and damage to the arm and boom. Do not move rock, It is strictly prohibited to travel when the breaker is in the contact with rock. Do not use rod as a lever. Do not put the rod into a crack in rock and move the rod to and fro to break the rock, otherwise the rod will be broken or the bracket will be damaged.HYDRAULIC BREAKER OPERATION MANUAL 6-4 §@ Do not operate the breaker in water and mud. Do not operate breaker when all components except rod are immersed in water and mud. Underwater usage of the breaker will cause internal damage to the breaker Consult Soosan for modifications if you have an underwater requirement. Do not allow the breaker to fall to a rock Falling down the breaker will apply excessive force to the breaker or the carrier, causing damage to the parts of the breaker and carrier.Do not do breaking operation at the stroke end of the carrier cylinder. Breaking operation conducted at the stroke end (when the cylinder is extended or retracted to a maximum extent) of respective hydraulic cylinders of the carrier will lead to damage to the cylinders and other parts of the carrier. Do not lift things with the breaker. Lifting things by hanging wire in the bracket or rod not only causes damage to the breaker but also is very dangerous.HYDRAULIC BREAKER OPERATION MANUAL 6-6 Warm-up of machine prior to operation. = Do not operate the machine righr after starting the engine. Idle the machine for warm-up. Warm the hydraulic oil sufficiently especially in winter or for in the cold place ~ Especially in winter 30~40°C(86~105'F) before breaker operation. = When operating the hydraulic breaker, idle the engine and operate the hydraulic the carrier's engine should be warmed up for 5 to 10 minutes breaker with a light load, 1 Stop operation when hoses are vibrating abnormally. Check the hoses on the high-pressure and low-pressure sides of the breaker for abnormal vibration. If they are vibrating abnormally, contact the nearest Soosan dealer. Avoid blank hammering Blank hammering accelerates wear and tear on breaker and carrier components and may result in failure of one or more components. Excessive blank hammering may be considered equipment abuse and may result in voiding warranties. In case of blank hammering, hammering sound changes. WM Operate the breaker at proper engine speed. Break rocks at the specified engine speed. Raising engine speed more than necessary does not strengthen hammering force but increase oil temperature to the detriment of piston and valve. When operating the breaker you must wear a eye protection, ear protection and breathing protection.7. Installation and Removal of the Hydraulic Breaker IM When the bucket and breaker operation alternately, the bucket and breaker can be easily exchanged by the hydraulic hoses and two mounting pins. However there is a tisk of hydraulic contamination accordingly, do installation and removal as follows. Timber (1) Move the carrier to stable ground free from mud, dust and dirt, (2) Place the hydraulic breaker on timber. (3) Stop the engine, turn off the main switch and deflate air from oil tank if itis. pressurized (4) Turn 90° the shut off vaive installed to the end of arm to prevent hydaulic from flowing out Close position Stop valve wo sos (Se) GW Open position (3) Loosen hose plug on the breaker arm. Collect small amount of oil flowing out at this time and put into a container. (4) Be careful to prevent mud or dust from entering oil hoses and pipe lines. Plug oil hoses with hose plug and pipe lines with union caps. Bind high~and low-pressure hoses with a wire to prevent them from getting mud.HYDRAULIC BREAKER OPERATION MANUAL 7-2 ST OIL HOSE PLUG The oll hose plug is used to plug the hose attached to the hydraulic breaker. It prevents mud or dust from entering the hose when the hydraulic breaker is removed from the carrier for bucket operation. MODEL] TYPE] P/N [TYPE] P/N | O-RINGU#S) soi0 [#5 | Coston] #4] comm] — sa20 | #5 | cosioo| #4 | Coase} _— 830 | #5 | cosioo| #4 | Coasza | #3 sBa5 | #5 | Co4i00] #4 | Cco4332 7 { ] S640 | #5 | coaioo| #4 | coasse | — seas #5 | coaool #4 coasse | _— a €] B45 | #3 | cratoo| #4 | c1aa72 = E saso|¥alciaiool eal crasr2] — [ } B60 | #9 | coaton | #4 | c340s0 | 2656004 070 | #3 | cearo0| #4 | ca40s0 | 2a5c00 #5 seat | #3 | caaioo| #4 | C3405 | 2856004 se100| #3 | caaioo| #4 | caa0s0 | 2856004 sB121 | #3 | coatoo] #4 | caasos | 2a5c005 86130 | #3 [ costo | #4 | caas06 | 2856005 sei40 [#3 | ceatoo | #4 | coas06 | 2856005 geist [ #3 | ceatoo | #4 [ csas06 | 2ase005 MEUNION CAP The union cap is used to cap the piping bracket attached to the cartier for prevention of the piping bracket from being smeared with mud during bucket operation. ‘ge10 | #5 | 2715002] #4 | co1is2 ‘se20 | #5 | e7iso02| #4 | cotis2 = seo | #5 | 27ie002[ #4 | corse = 8635 | #5 | 2716002] #4 | Co11s2 = se40 | #5 | 2715002| #4 | Co11s2 = #4 | corts2 = seas | #5 [2715002 #4 ‘645 | #3 [erisoc2] #4 | ciita9| 2656003 seo | #3 |271s062[ #4 | crii49 | 2856003 S660 | #3 [2716063] #4] C21132] 2856004 #3 se70 | #3 | 2715063 #4 | C21132| 2856004 set | #3 |2riso6a] #4 | c2its2| 2856004 s6100 | #3 | 2715003] #4 | c2tis2 | 2856004 sB121 | #3 | 2715064] #4 | c3t175 | 2656005 88130 | #3 | 2715064] #4 | osii75 | 2850005 175 | 28560 175 | 2856005) #5 e140 | #3 | 2715064] #4 seist | #3 | 2715064] #48. Repair and Inspection WM Tightening Torque & Gas Pressure rea pose] unr | $8241 se30| S635] S800] seas) s45| sso] sBe0| se70 sar 40]se5 wwousnsor | A fkg-m| so | 30] 35 | 20 | 65 | 100] 150] 240 | 260 | 270 | 300 | 00 | aso | aso cca S20 BIg z : = |s0~85}60~e=f60~69{o0-cs}o0-a4 recmrvare cre |G lag) — | aS as | as 35 | 65 20, Po D fromm - ws fas }as | as | as svactet aie Bor | kgm! 60 | 80 | 80 | 100 | 100 | 148 | 145] 200 | 250] 250 | 250 | aso | 20 | a0 1e5| 165 235 | (235), 5 7eah| (702 Back eed kaler| 16.5] 165 | 165] 65] t65] 15] ies} ies| os] ws as Pressure (os) | (285)| (208) c235)| (238) (238) | (235)| (230)| as) | 23s)] (285), “Recumalser aa 38 wePrecawe | © Lipsi) (ree) aveteckvave |G fig-m)6-t)16-1ali6~19ht6~16|16-10f:6-teh6~r0) 6~r4f16~re] 16-18 16~ra 16 vaveaastner | H [a-m = ~ be. 1 |ko-mft6~tafie-re foe~2efoe~2ofso~2e}32~2e] 32-25} 22-29} 36—40fas~ao]35~20 cracamavane | [harm] 4 os~40f5~aofos~40) 35~cofas~aofas-4o]35~aols~ PACK HEAD GAS PRESSURE AC THR 01 ROUGH B CHARGING VALVE valve anwusr D: BRACKET ae G AIR CHECK VALVE eaten B: ACCUMULATOR SOCKET Bi ACCUMULATOR GAS PRESSURE ©: ACCUMULATOR COVER BOLT * GREASING 206 pouting after 1 hour usingHYDRAULIC BREAKER @ Daily Inspection before operating OPERATION MANUAL 8-2 Before starting operation, be sure to inspect the breaker refering to the following table. Inspection Item Inspection Point Remedy ~ Looseness, missing and damage to bolts and nuts ~ Through bo = Bracket mounting bolt Check looseness, Relighten to correct lightening torque. = Looseness of hose fittings, visible damage to hoses and oil leakage ~ Hydra ~ Oil hi ilic piping for breaker = Retighten sufficiently ~ Replace when damaged ‘Abnormal oll leakage a6 © 4 Co Connection of back head and oylinder = Gap berween front head and rod 3 But small leakage is normal. = Consult with Soosan for further inspection. = Abnormal wear and cracks rod, 6, (ey Ow) = 10d =I the fod is deformed, burred and worn out, be repaired. If the rod is excessively worn out, be replaced ~ If the tod is cracked, be rept: aced.| Inspection Item a Inspection Point Remedy = Greasing U oro 7. — Bb as = Grease 5-10 times before start and every 2-3 hours with a gre~ ase gun. Grease while the rod is on the ground and it is pushed against piston = Grease to front head. Level of hydraulic oil = Contamination = Conditions of hydraulic of Contamination of hydraulic ol! varies with operating conditi~ ons. = Judge it by the color of hyd aulic oil, Follow the criteria set by Soosan. = When contamination is exce— ssive, drain and flush the hydraulic oil tank and then ad [ H 0. e] arTT 3s cushion. (apply to silence type) = Down cushionHYDRAULIC BREAKER OPERATION MANUAL 8-4 I Regular Inspection & Maintenance Regular inspection is essential for keeping hydraulic breaker operating in the best condition and extending the durability. Customers are recommended to contact the service station for inspection within 6 months after delivery. Replacement & Breakage of Rod = Rod is deformed of burrs produced in a long-term use = If the rod tip is worn out, rod is liable to slip. Grind the rod tip to sharpen the edge. = If the rod tip is sharpened many times, the hardened surface layer will disappear and the rod will be worn out rapidly. In this case, replace with a new rod = If the gap between rod and front cover is large, the piston fail to fit in rod to cause damage to the piston or the rod. 1) Replacement @ Put the breaekr horizontally on the timber. @ Remove the spring pin(SB43 below) or rubber plug ($845 above) using a pin bar. @ Set round bar on the opposite side, and push the stop pin with a hammer @ Remove the rod pin In removing the rod pin, be caretul falling of rod and ® Wins r nylon sling aroun rod and remove ® Wind rope or nylon sling around the rod and removs Ro Top ® Before installing a new rod, check wear, breakage and score, Remove burrs and swelling from the dis assembled rod pin with a grinder. Excessively deformed tod pin will make replacement of rod difficult. Rod pin is requited to be checked every 100 to 150 hours of operation L___J © Grease sufficiently to inserting part of front head ¥ Use of non genuine rod will void the warranty of breaker. I Breakage of Rod The service life of the rods depends on the manner of handling them. The rod can sufficently withstand the vertically acting load, but is weak to the perpendicularly acting load. Especially, the rod is affected by the negative conditions such as force hy eranina oneration. tilted blowing. wrenching and idle strokes etc.Seo\‘\GMWMe,,”?}\_55GtQ]SQF Se There are several ways of breakage of the rod. Each cause of the breakage can be infered:by observing the breakage section. Further, the breakage case which is not caused by low quality materials or insufficient heat-treatment but by wrong way of handling which the manufacturer is not responsible for the breakage. The breakage section has the origin on the outer surface, the narrow area of fatigue breakage and the wide area of rough grey area, and final breakage part has the the share-lip form. Such as undulation on the breakage section and its inclination to the right and left witness that the breakage is caused by excessive force which excessive force which exceeds the toughness of the rod. Such the breakage is supposed to occur owing to careless handling of the rod. To avoid such the breakage more carefulness and attention is required in handling the breaker. DON opt, z Typical fractures caused by excessive bending of the rod. Warranty claims rejected Stress concentration point at 90° to the rod pin plate. Sharp lip 7 (Starting point) Rough Grey Area Typical fractures caused by levering tool while buried in the burden. Warranty claims rejected. Flat type rod worn more than 45mm or moil type and wedge universal type rods worn back more than 75mm of working end classed as reasionable life. Warranty claims rejected,HYDRAULIC BREAKER OPERATION MANUAL 8-6 Assembly and Disassembly of Rubber Plug In disassembling the front head pin and stop pin, assemble or disassemble with following method. 1) Assembling the rubber plug @ Method #1 @ Method #2 uber Plug a q Hammer 2) Disassembling the rubber plug @ Method #1 @ Method #29. Wear Tolerance Wear tolerance of each kind expendable parts come to decide. The usage of exceeding the wear tolerance causes fatal damage to breaker. Prevent the damage through the regular inspection and exchange of expendable parts including seals and all kinds of bushes. Our company is not responsible for the flaw using in exceeding the wear tolerance of the expendable parts, MSEAL and O-RING Quality Guaranteed Period : 3 months Since hydraulic breaker operates at high-pressure and high-temperature, leakage or scratch could be occured by friction, wear and breakage of seals. Considering pressure, temperature, viscosity of oil, a little leakage is accepted to be normal. But in case of abnormal leakage, replace as a new ones. To prevent fatal defect periodical replacement is carried out every 3 months without external leakage of breaker. Although the breaker is not operated in a long time, replace seals periodically to prevent rust, corrosion of oil and transformation of seals. FRONT COVER, THRUST BUSH UNIT(mm) c NEW MODEL] Inside Dia $10 40 $820 45 7 tupust | $830 53 55 Hse = THRUST BUSH 60 62 (Measure at center) 68 n 75 79 85 a9 $850 100 105 B60 125 130 $870 135 140 8881 140 146 FRONT Coven [$8190 150 156 sB121 186 4161 185 161 $8130 165 171 FRONT COVER $8140 165 171 (Measure at 10am) SB151 175 181HYDRAULIC BREAKER OPERATION MANUAL 9-2 Laan e ee el RING BUSH UNIT(mm) rr seo | 40 2 8.75 7 se20 [45 a7 10.25 a ses0 | 53 5 85 6 — SB35 60 62 10.5 75 Ls seo | 68 71 10.6 7.5 __| Wear area sea | 75 78 15 12 « seas | 85 29 24 2 — B50 | 100 105 17 14 |_| se00 | 125 130) a 28 {Measure at 30mm se7o | 195 140 32.5 29.5 seer | 140 146 40 a7 se100 | 160 156 ser2i | _155 161 senso | 165 7 seiao| 165 17 SB 7 17 ROD PIN UNITimm) NEW | REJECT Lenath_| Length 28 26 28 26 30 35 33 38 36 #2 40 seas |__54 51 seso | 60 37 seco 75 72 se70 | 62 7 N seat | 685 85.5 94 3 6 8 9% 93 % 33 99) 95.M@STOP PIN UNIT(mm) [ecm eee MODEL oundea. | outsdeds sep | 1 eee [8 | so [ es] 1 seas [7 i seo |e} 14 see [ 16 [4 seis | W78 | 163 sero | 178 | 155 soso [178] 168 seo [ 178 | 155 seer [| 18 seioo] ars} 65 serar[ 17s} 88 $B130 17.5 15.5 88140 $8181 MI FRONT HEAD PIN UNIT(mm) MODEL] owas bia | outside Ds seas] 20 18 saso | 26 24 saeo | 28 2a saro | 26 2a seat | 20 28 sa1o0 | 26 28 sero] 26 2 seico} 26 28 $8140 26 24 SB151 36 34 Measure Diameter Measure DiameterHYDRAULIC BREAKER OPERATION MANUAL 9-4 ‘Wear Limit ROD UNIT(mm) MODEL (on TYPE) teat sero 297 200 sezo| 326 200 sao] 330 200 seas ara 200 saa] 405 250 seas] 467 367 250 sso] _sét 361 250 60] 650 450 300) sero] 701 501 350 ee seer | _762 562 400 - - ser00] 964 654 450 sei2i| 1500 713 500 ser30| 1600 752 500 sera] 1600 752 500 1600 a8 550 PISTON uNiT(mm) Moog] eran |_tanath seo] 159 158 sezo] 169 168 ( seo] 168 167 seas] 196 196 seao| 19 188 |) + —_— spaa|__251 250 spas | 285 284 seco] 275 274 seco] 340 338 L Wear Limit 318 316 324 322 357 355 New Part 385 383 ——— - rr an a3 an seis] 518 51610. Inspection and Charging of N, GAS at Back Head Z\ WARNING I CHARGING GAS PRESSURE CHANGES ACCORDING TO THE ROD CONDITION LAY DOWN THE HAMMER AND LET THE ROD EXTEND FULLY TO CHARGE GAS. STAY CLEAR OF THE ROD WHILE CHARGING THE BREAKER WITH GAS. METHE ROD MAY BE IMPACTED BY THE PISTON AND FORCED OUT ABRUPTLY, WHEN THE THROUGH BOLTS ARE CHANGED OR THE BREAKER BODY IS DISASSEMBLED. DISCHARGE N, GAS BEFORE WORK. MITAKE SPECIAL CARE TO HANDLE AND SRORE THE N; GAS CYLINDER AS IT IS HIGH ~PRESSURIZED CONTAINER MUSE NITROGEN GAS ONLY. BACK HEAD GAS PRESSURE 16.5kg/a# (235psi) ON THE BACK HEAD SURFACE TEMPERATURE AT 20'0(68°F) SEE "CONVERSION TABLE FOR CHARGING N, GAS PRESSURE TO BACK HEAD" Ml Inspection of Nz Gas Back Head 1) Make sure if the cap and vaive of the 3-way valve assembly(S) are fully tightened Screw the 3-way valve assembly(5) into the charging valve of the back head after removing the plug. 2) AL this time the handle must stand up to prevent the gas from coming out. 3) Push the handle into the charging valve fully, so the gas pressure inside the back head is indicated on the pressure gauge 4) When the gas pressure is normal, unscrew the 3-way valve assembly after discharging gas inside the 3-way valve assembly 5) When the gas pressure is higher or lower, charge it as described below. Mi Charging of Np gas into Back Head 1) Connect the charging hose(4) to N2 gas cylinder(1) after screwing the bombe adapter(3) onto adapter nut(2) and installing them to the Ne gas cylinder. 2) Connect the 3-way valve assembly(5) to the charging hose(4) after unscrewing the cap on the 3-way valve. 3) Install the 3-way valve assembly(5) to the charging valve of the Back Head. At this time the handle of the 3~way valve assembly must be up position to prevent the gas from coming out 4) Push the handle of the 3-way valve assembly fully and tum the handle of the Ne gas cylinder counterclockwise gradually to charge gas. _HYDRAULIC BREAKER OPERATION MANUAL 10-2 5) When the gas pressure exceeds 10% higher than the specitied pressure, close the Np gas cylinder by turning the handle clockwise. 6) Leave the handle of 3-way valve assembly up. Generated pressure makes it return back to original position naturally. 7) In order to discharge N, gas in the charging hose(4) and the 3-way valve assembly, urn the relief valve counterclockwise. 8) Remove the charging hose(4) from the N; gas cylinder(1) and the 3-way valve assembly(5), and screw the cap onto the 3-way valve assembly. 9) Push the handle of the 3-way valve assembly fully, and the gas pressure inside the Back Head is indicated on the pressure gauge. When the pressure is higher, discharge a small amount of gas from the Back Head by repeatedly opening and closing the valve and then gas pressure falls to the specified pressure. 10) When the gas pressure reaches to the specified pressure, close the valve and release the handle. 11) Open the valve completely and discharge gas inside the 3-way valve assembly. Remove the 3-way valve assembly from the charging valve of Back Head and install the plug to the charging valve. At this time prevent contamination from entering the breaker Conversion Table for charging nitrogen gas pressure to Back Head (Depends on the temperature of Back Head surface) Back Head rae | 4 20/68 | 30/86 | 40/104 Surface Temperature (‘0 /*F) | ° Mee lie U oe Back Head Gas Pressure (ka/cwt / psi) 15.5 / 220) 16/228 |16.5/ 235] 17/242 |17.5/ 249) Back Head Sticker (C02135) (Appears on the Back Head charging valve) USE ONLY FILL WITH No GAS! GAS PRE-CHARGE PREUUSRE 16.5kq/cm"{235PS), AT 20°O(68°F) CAUTION — PRESSURIZED VESSEL. DISCHARGE PRIOR DISASSEMBLY.IN, Gas charging tools to Back Head ITEM PART No. PART NAME 061204 1 SET Nz Gas Charging Set 1 2900003 1 Nz Gas Cylinder 2 coti2t 1 Bombe Adapter Nut 3 091122 1 Bombe Adapter 4 2651001 1 Synflex Hose 91142 1 B-3way Valve Assembly Handle Conversion table for charging N, gas pressure to back head if part Ne gas sealing pressure(kg/cn') 0 2 40 60 Back Head Surface Temperature(°C)HYDRAULIC BREAKER OPERATION MANUAL 11-1 11. Inspection and Charging of Nz gas in Accumulator ZX _ WARNING TAKE SPECIAL CARE TO HANDLE AND STORE THE N; GAS CYLINDER AS IT IS HIGH-PRESSURIZED. CONTAINER USE NITROGEN GAS ONLY. MLWHEN DISASSEMBLE THE ACCUMULATOR , MUST DISCHARGE NoGAS BEFORE WORKING. 100 NOT TOUCH ON THE ACCUMULATOR SURFACE WHEN WORKING. IGE SURE TO USE THE 3-WAY VALVE ASSEMBLY FOR CHARGING THE N)GAS. IF CHARGING GAS, LEAKS DIRECTLY FROM THE CYLINDER , DIAPHRAGM MAY BE BROKEN OFF LIF CHARGING FOR HANDLING Np GAS TO ONLY THE ACCUMULATOR, MAKE SURE THAT THE ACCUMULATOR BODY AND COVER ARE TIGHTENED FULLY. IESTANDARD ACCUMULATOR GAS PRESSURE 55ka/at (783psi) ON THE ACCUMULATOR SURFACE TEMPERATURE AT 20°C(68'F) SEE "CONVERSION TABLE FOR CHARGING N; GAS PRESSURE TO ACCUMULATOR" I Inspection of Ne gas Accumulator 1) Make sure if the cap and valve of the 3-way valve assembly(6) are fully tightened. 2) Remove the cap(11) from the accumulator and tighten the 3) Check if O-rings(6)(8) ate installed to the bushina(7). Remove the warging valve (12) fully plua(9) and screw the bushing 4) Install the bushing(7) to the 3-way vaive assembiy(5) 5) Loosen the charging valve(12) gradually. The charging pressure is indicated on the pressure gauge. 6) Close the valve clockwise when the gas pressure is normal. If the gas pressure is higher, repeat loosening and tightening the relief valve of 3-way valve assembly. The pressure is lowered gradually 7) Loosen the relief valve of the 3-way valve assembly to discharge the Np gas in the 3-way valve assembly(5) 8) Remove the 3-way valve assembly(5) and tighten the plug(9) and cap(11) Charging of N2 gas into Accumulator 1) Connect the charging hose(4) to Np gas cylinder(1) after screwing the bombe adapter(3) onto adapter, nut(2) and installing to the Ne gas cylinder. 2) Connect the 3-way valve assembly(6) to the charging hose(4) after unscrewing thecap on the 3-way valve assembly. 3) Remove the cap(11) form the accumulator and tighten the charging valve(12) fully. 4) Check if O-rings (6)(8) are installed to the bushing(7). Remove the plua(9) and screw the bushing. 5) Loosen the accumulator charging valve(12) after checking if bushing(7) is installed to tha Iowa value accembly6) Turn the handle of the Np gas cylinder counter clockwise slowly to charge gas 7) Charge gas in accordance with the conversion table for charging N: gas pressure to accumulator. 8) Turn the handle of the Np gas cylinder clockwise to close the cock: 9) Close the accumulator charging valve(12). 10) Loosen the relief valve of the 3-way valve assembly to discharge the N2 gas remaining in the charging hose. 11) Remove the charging hose, 3-way valve assembly and bushing and tighten the plug(9) and cap(11) Conversion Table for charging nitrogen gas pressure to Accumulator Back Head Surface Temperature (‘0 / ‘F) o/s2 | 10/50 | 20/68 | 30/86 | 40/104 Back Head 53 ! 3 Gas Pressure (ho/er / psi) | 51/780 | 88/785 | 88/780 | 87/818 | 59/830 W Accumulator(A) Sticker (C61210) appers on the accumulator body Caution | Pressurized container ! Discharge prior to disassembly ! Do not open without reading the Operation Manual or consulting the authorized service personnel ! 012199 NvSoos @ Accumulator(B) Sticker (C61211) ~ appers on the accumulator body Date of construction Temperature(Max) Ea Volume, 1.76 Fill Material Only nitrogen gas ‘ACCUMULATOR PRECHARGE 55kg/cn?, 780psi PRESSURE (at 200 /68°F) SOSAN C5121HYDRAULIC BREAKER OPERATION MANUAL 1 MN Gas Charging Tools to Accumulator ITEM PART No. ay PART NAME 1 2900003 i Nz Gas Cylinder 2 091122 1 Bombe Adapter 3 cgii21 1 Bombe Adapter Nut 4 2651001 i Syntlex Hose 5 c9ita2 1 B-3 Way Valve Assembly 6 2850010 1 O-Ring id ug1414 1 O-Ring Hex Bushing 8 2850014 1 O-Ring 9 81276 1 O-Ring Plug 10 2850014 2 O-Ring " 81275 i O-Ring Cap 12 81266 1 Accumulator Charging Valve 13 2850003 O-Ring Handle Convesion tale fo charging Ne gis pressure to accumulate is - N gas sealing pressure(ka/om) . 2m 0 o 8 Accumulator Surface Temperature(’C)