H140GC & H140GCS Hydraulic Breakers

GESR0853-01
June 2019
Service Manual
H140GC & H140GCS Hydraulic Breakers
KSX 1 - UP
WHC 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.
◆ Study this manual before installing, operating or maintaining this equipment.
◆ This hammer is a powerful tool. Used without proper care, it can cause damage of product or serious
injury.
◆ Use it properly and use it well. Pay particular attention to all safety messages.
◆ To use the hammer correctly, you must also be competent operator (assistant) of the carrier machine.
◆ Do not use or install the hammer if you cannot use the carrier machine.
◆ Do not rush the job of learning. Take your time and most important, take it safely.
◆ If there is anything you do not understand, ask your CAT dealer. He will be pleased to advise you.
◆ It may cause serious injury and death when operators do not follow operational 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 manual and warning symbols in the manual are very important for safety.
◆ Operators should maintain those manuals in a good condition and replace them if damaged.
◆ It is strongly recommended that genuine spare parts supplied by CAT must be used at all times.
◆ Use the right tools to install, remove, repair or replace the hammer and spare parts.
◆ 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
◆ FOREWORD ................................................................................................................................................................................. 2
◆ TABLE OF CONTENTS ................................................................................................................................................................. 3
◆ SAFETY ALERT SYMBOLS .......................................................................................................................................................... 5
◆ INTRODUCTION OF HYDRAULIC BREAKER ............................................................................................................................... 6
◆ PRODUCT SERIAL NO. ............................................................................................................................................................ - 7 -
◆ PRODUCT WARNING LABEL ................................................................................................................................................... - 7 -
SAFETY INFORMATION
1. BASIC INFORMATION ...................................................................................................................................................................... 12
2. PRECAUTION BEFORE OPERATION .............................................................................................................................................. 14
3. PRECAUTION DURING OPERATION ............................................................................................................................................... 16
4. PRECAUTION AFTER OPERATION ................................................................................................................................................. 19
OPERATION
1. HAMMER INFORMATION ................................................................................................................................................................. 21
1-1. PART NAME & STRUCTURE.................................................................................................................................................. 21
1-2. GENERAL SPECIFICATION ................................................................................................................................................... 22
1-3. ADVANTAGE OF “B-SERIES” BREAKER................................................................................................................................ 24
1-4. FUNCTION & FEATURES ....................................................................................................................................................... 25
1-5. EXTERNAL DIMENSIONS OF EACH MODEL ........................................................................................................................ 30
2. INSTALLATION & REMOVAL OF BREAKER ..................................................................................................................................... 32
2-1 KEY POINTS FOR SELECTING HAMMER .............................................................................................................................. 32
2-2 HYDRAULIC CIRCUIT ............................................................................................................................................................. 33
2-3 INSTALLATION ........................................................................................................................................................................ 34
1) DIMENSION OF TOP PLATE ................................................................................................................................................. 34
2) TOP BRACKET ASSEMBLY................................................................................................................................................... 35
3) PIPE FLUSHING.................................................................................................................................................................... 36
4) INSTALLATION OF BREAKER .............................................................................................................................................. 37
5) CONNECTING IN/OUT LINE HOSE....................................................................................................................................... 39
6) CONNECTION PORTS OF THE HAMMER ............................................................................................................................ 40
2-4 REMOVAL OF BREAKER ........................................................................................................................................................ 41
2-5. CHECK POINTS WHEN SETTING HYDRAULIC LINE TO BREAKER..................................................................................... 43
2-6. WARMING UP OPERATION GUIDELINE................................................................................................................................ 44
1) WARM-UP OPERATION GUIDELINE FOR DAILY BREAKER OPERATION ........................................................................... 44
2) WARM-UP OPERATION GUIDELINE AFTER LONG TERM STORAGE ................................................................................. 45
2-7. OPERATION PROCEDURE .................................................................................................................................................... 47
1) PREPARATION OF SAFE OPERATION ................................................................................................................................. 47
2) PRECAUTION BEFORE OPERATION ................................................................................................................................... 48
2-8. CORRECT OPERATION ......................................................................................................................................................... 49
3. STORAGE ........................................................................................................................................................................................ 55
3-1. SHORT TERM STORAGE ...................................................................................................................................................... 55
3-2. LONG TERM STORAGE ......................................................................................................................................................... 56
3-3. OPERATION AFTER LONG TERM STORAGE ....................................................................................................................... 57
4. TROUBLE SHOOTING ..................................................................................................................................................................... 58
5. OPERATING PRINCIPLE .................................................................................................................................................................. 60
6. SPECIAL APPLICATION ................................................................................................................................................................... 64
6-1. UNDERWATER JOB ............................................................................................................................................................... 64
MAINTENANCE
1. GENERAL PRECAUTION ................................................................................................................................................................. 71
2. PERIODICAL INSPECTION & SCHEDULE ....................................................................................................................................... 73
2-1. EVERY 2 HOURS INSPECTION ............................................................................................................................................. 73
2-2. DAILY INSPECTION ............................................................................................................................................................... 73
2-3. MONTHLY INSPECTION ........................................................................................................................................................ 74
2-4. YEARLY INSPECTION OR EVERY 600 HOURS..................................................................................................................... 75
3. HYDRAULIC OIL............................................................................................................................................................................... 76
4. LUBRICATION .................................................................................................................................................................................. 79
5. NITROGEN GAS CHARGING ........................................................................................................................................................... 81
5-1. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF BACK HEAD ................................................................................... 81
5-2. SPECIFIED NITROGEN GAS PRESSURE FOR BACK HEAD ................................................................................................ 86
5-3. INSTRUCTIONS FOR GAS PRESSURE INSPECTION .......................................................................................................... 87
5-4. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF ACCUMULATOR ............................................................................ 90
5-5. SPECIFIED NITROGEN GAS PRESSURE FOR ACCUMULATOR.......................................................................................... 96
6. WEAR LIMIT FOR CONSUMABLES ................................................................................................................................................. 97
3
TABLE OF CONTENTS
7. TORQUE ........................................................................................................................................................................................ 100

8. REPAIR & REPLACEMENT ............................................................................................................................................................ 104
8-1-1. OPEN HOUSING ............................................................................................................................................................... 104
8-1-2. BOX HOUSING.................................................................................................................................................................. 105
8-2. SIDE ROD ............................................................................................................................................................................ 106
8-3. SEAL REPLACEMENT ......................................................................................................................................................... 108
8-4. PISTON ................................................................................................................................................................................ 110
8-5. TOOL & TOOL BUSHING ...................................................................................................................................................... 111
9. DISASSEMBLE THE HAMMER POWERCELL ................................................................................................................................ 114
10. ADJUSTMENT .............................................................................................................................................................................. 119
10-1. CYLINDER ADJUSTER....................................................................................................................................................... 119
TOOL FAILURE ANALYSIS

1. GUIDELINE FOR VARIOUS TOOL FAILURES ................................................................................................................................ 121
1-1. TOOL FAILURE ACCEPTED UNDER GOODWILL ................................................................................................................ 123
1-2. TOOL FAILURE REJECTED UNDER WARRANTY ............................................................................................................... 124
REUSABILITY GUIDELINE FOR PISTON & CYLINDER

1. POTENTIAL CAUSES OF PISTON & CYLINDER SCRATCHES ...................................................................................................... 130
2. RESUABILITY GUIDELINE FOR PISTON ....................................................................................................................................... 131
2-1. GENERAL UNDERSTANDING OF PISTON .......................................................................................................................... 131
2-2. ACCEPTABLE CASES FOR PISTON REUSE ....................................................................................................................... 132
2-3. UNACCEPTABLE CASES FOR PISTON REUSE.................................................................................................................. 135
3. RESUABILITY GUIDELINE FOR CYLINDER................................................................................................................................... 138
3-1. GENERAL UNDERSTANDING OF CYLINDER ..................................................................................................................... 138
3-2. ACCEPTABLE CASES FOR CYLINDER REUSE .................................................................................................................. 139
3-3. UNACCEPTABLE CASES FOR CYLINDER REUSE ............................................................................................................. 142
4. REPAIR GUIDELINE FOR PISTON & CYLINDER REUSE ............................................................................................................... 145
5. RECOMMENDED MEASUREMENT GAUGES FOR REPAIR SERVICE .......................................................................................... 147
6. DIMENSIONAL GUIDELINE FOR WEAR LIMIT OF PISTON & CYLINDER REUSE ......................................................................... 148
7. REASSEMBLY GUIDELINE ............................................................................................................................................................ 149
WARRANTY .......................................................................................................................................................................................... 150
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 only proper means of maintaining and
identifying parts for a specific product.
WHC
< H140 >
KSX WHC
H140GC H140GC S
-7-
PRODUCT WARNING LABEL
HAMMER LABEL
8
PRODUCT WARNING LABEL (OPEN TYPE)
HOUSING LABEL L
9
PRODUCT WARNING LABEL (BOX TYPE)
HOUSING LABEL L
10
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.
11
SAFETY INFORMATION
1. BASIC INFORMATION
UNDERSTANDING OF OPERATION MANUAL
Not observing operational guidelines may cause serious injury or death in extreme case. Operator
should follow operating guidelines of excavator & 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 are very important for safety. Operator should maintain those manuals in a good condition
and replace them if damaged.
OPERATION MANUAL & WARNING OBSERVATION
Operators should not operate machine if not in operative condition due to tiredness, lack of sleep
and medication. Operators should take regular medical check up to maintain good health condition.
12
SAFETY INFORMATION
WEARING SAFETY GEAR
Operator should 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-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.
13
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 damaged part if
found.
The following parts should be checked:
- Leakage of the hydraulic system or other functioning parts

- Bolt loose or missing
- Back head gas pressure
14
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.
15
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.
16
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
17
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.
USE THE BREAKER ONLY FOR THE SPECIFIED WORK
If using the breaker for crane work or suspending heavy objects, serious injury, accident, or death may
occur.
COLLISION WARNING
Operator should be careful when operating indoors or in narrow places.
18
SAFETY INFORMATION
4. PRECAUTION AFTER OPERATION
CAUTION WHEN RE-FUELING
Flammable fluids such as fuel and oil should be handled carefully. Keep away flammable material from
equipment. Do not smoke when re-fueling. Stop engine completely when re-fueling.
Be careful not to over flow fuel tank.
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.
- Park excavator on flat and solid ground.

- Place all levers in neutral position
- Shut down engine completely
- lock the door to prevent unauthorized person's operation
19
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.
20
OPERATION
1. HAMMER INFORMATION
1-1. PART NAME & STRUCTURE
< H140 >
21
OPERATION
1-2. GENERAL SPECIFICATION
H140 GC
MODEL
UNIT TOP MOUNT
DESCRIPTION CB & CB2 Linkage DB Linkage TB Linkage
WORKING
kg 2981 3077 3134
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 moil tool and top bracket
22
OPERATION
H140 GC S
MODEL TOP MOUNT
UNIT
CB & CB2 Linkage DB Linkage TB Linkage

DESCRIPTION
WORKING
kg 3077
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 moil tool and top bracket
23
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.
24
OPERATION
1-4. FUNCTION & FEATURES
SEAL HOUSING
BACK HEAD VALVE BLOCK
ACCUMULATOR
CYLINDER
PISTON
FRONT HEAD
TOOL BUSHING
SIDE ROD TOOL
UPPER BUSHING
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.
25
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 >
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.
26
OPERATION
< SIDE ROD >
The front head, cylinder and back head are secured with the four side 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.
27
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
excessively improved hammering force.
NOTE
The piston is NOT chromed and cannot be chromed as a repair process.
28
OPERATION
<TOOL>
Use a tool suitable for the application
TYPES & APPLICATION
TYPE OF
SHAPE GENERAL APPLICATIONS
TOOL
Multi-use application, breaking
MOIL hard rock. concrete and
bedrock, etc.
Breaking concrete, bedrock,
CHISEL trenching, and operation on
slopes.
Breaking concrete, bedrock,
BLUNT trenching, and operation on
slopes.
Multi-use application, breaking
CONE hard rock, concrete and
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 H140
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
29
OPERATION
1-5. EXTERNAL DIMENSIONS OF EACH MODEL
< H140 OPEN HOUSING > < H140 HAMMER >
30
OPERATION
< H140 BOX HOUSING > < H140 HAMMER >
31
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.
32
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.
33
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.
< H140 >
UNIT : mm
MODEL A B C D E F G H I J K
OPEN 12-Ø39 175 220 175 730 130 275 130 635 50 80
H140
BOX 12-Ø39 240 250 240 830 200 200 200 700 50 50
34
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 :
< H140 >
1. TOP BRACKET 2. HEX. BOLT 3. PLAIN WASHER
4. SPRING WASHER 5. HEX. NUT
35
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 H140
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.
36
OPERATION
4) INSTALLATION OF BREAKER
DANGER
Operator should check for any possible dangers 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 at the position where the pin exits.
After fixing the top bracket to the housing, prepare for installing the 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 pin hole
of the breaker's top bracket(4).
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
37
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 properly 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.
38
OPERATION
5) CONNECTING IN/OUT LINE HOSE
1. Stop the engine of the main carrier, discharge pressure from the hydraulic oil tank and do not move
the operation lever.
2. Check that stop valves on both side of the arm are fully "CLOSED". If not, use the spanner and turn
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.
4. Connect the "IN" & "OUT" hoses to the stop valves on 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.
39
OPERATION
6) CONNECTION PORTS OF THE HAMMER
1. IN - LINE hose (High pressure)
2. OUT - LINE hose (Low pressure)
< H140 >
Following is the specification of IN / OUT port in the fitting hammers.
HOSE ASSEMBLY PIPE LINE SIZE

MODEL REMARK
IN OUT IN OUT
H140 PT 1 1/4″ PT 1 1/4″ UNF 1 11/16 UNF 1 11/16
40
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-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 the flat, safe place.
2. Stop the engine of main carrier, and release the pressure trapped inside the hoses and oil tank.
Wait tem minutes for oil pressure to drop.
3. Turn the stop valves (1) of both sides to the fully closed position.
4. Remove the oil hose. (The residual pressure may remain in the pipe-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
41
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 check for any possible dangers 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 at the position where the pin exits.
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, replace or repair)
10. Start the engine, and slowly operate the MCV to check the oil leakage from the pipe line.
NOTE
Nitrogen charge must be installed prior to initial start up of hammer.
NOT charged from factory.
42
OPERATION
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
⚫ Stop the carrier engine. Assemble the high pressure gauge on the hammer (350 bar gauge)
measuring port.
⚫ 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.
⚫ Read the average pressure from the high pressure gauge of operating pressure.
⚫ Stop the carrier and remove the gauge. Tighten the plug of the pressure measuring port.
3) PIPE LINE CONDITION
⚫ 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
43
OPERATION
2-6. WARMING UP OPERATION GUIDELINE
1) WARM-UP OPERATION GUIDELINE FOR DAILY BREAKER OPERATION
⚫ Temperature Range
The hydraulic oil intended for the main carrier can be utilized for hammer operation. Warm up
procedure is required depending on the ambient temperature.
A. The standard oil temperature for breaker operation is recommended between 10 ℃ (50 ℉)
and 80 ℃ (176 ℉) and the lowest oil temperature should be 10 ℃ (50 ℉).
B. High ambient temperature [above 30 ℃ (86 ℉)]: Use oil with sufficient viscosity. If the
hydraulic oil is too thin in high ambient temperature, the operator may find slow and irregular
strokes on the breaker operation. In high ambient temperature and summer, daily warm up
procedure is also carried out to protect seals and diaphragm of breaker.
C. Low ambient temperature [below 0 ℃ (32 ℉)]: If the oil is too thick, the operator may find
start up difficult. The breaker should not be operated until the oil temperature is over
10 ℃. If the temperature of the core breaker parts such as cylinder, piston and
accumulator have similar temperature level of the oil temperature (over 10 ℃), seals and
diaphragm may have lower risk from unexpected damage. Keep minimum oil temperature
requirement through the warm up operation to protect and improve functionality of seals and
diaphragm of breaker.
D. The proper temperature range of the hydraulic oil is between 50℃ (122 ℉) and 80℃ (176
℉).
E. If the temperature of the hydraulic oil exceeds 80℃ (176 ℉), the hydraulic oil cooling
system needs to be checked whether it is working properly. Otherwise, an auxiliary oil
cooling system is needed. IF the breaker is operated over 80℃ (176 ℉), the life of the
seals and the membrane can be reduced.
F. Consult your CAT dealer and also refer to the Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more information.
G. If the working tool is exposed to temperatures below 0 ℃(32 ℉), it can break with sudden
operation. The working tool has to be carefully warmed up by following the daily warm up
procedure of the breaker below.
⚫ Warm up procedure for daily breaker operation
A. Before breaker operation, the operator should let the excavator idle to increase the
temperature of the oil in the main carrier, see guidelines from excavator manufacturer on
idling operation.
44
B. Once the idling operation is completed, the operator should conduct warm up operation for
the breaker. The operator conducts the breaker operation with the lowest operation mode
such as engine speed dial 2 or 3 for 5 seconds and repeat 5 times. Then, the operator can
increase the engine speed dial to 4 or 5 and operate for 20 and 30 minutes to complete the
daily warm up operation.
C. After the completion of “B” above, the operator can operate the breaker normally.
D. Operate the breaker at 90 degrees to the working surface and do not operate in one spot
for more than 15 seconds if the tool is not penetrating.
E. Without sufficient warm up operation for daily breaker operation, the sudden operation
under high pressure can cause seizure due to the breakage of the oil film.
2) WARM-UP OPERATION GUIDELINE AFTER LONG TERM STORAGE

(APPLIED FOR OVER 6 MONTHS’ LONG TERM STORAGE)
⚫ Warm up procedure after long term storage
A. Check the corrosion on the piston head.
B. Check N2 gas pressure level in the back head and keep or charge the level of 6 bar.
C. Install the breaker on the machine carrier.
D. Conduct the idling operation for the hydraulic circuit on the main excavator.
E. Operate the breaker at the lowest operation mode such as engine speed dial 2 or 3 for 5
seconds and continue operating at this mode for minimum 10 minutes after the breaker is
vertically set up on the obstacle to break.
F. Operate the breaker at engine speed dial 4 or 5 for minimum 10 minutes after the breaker is
G. Operate the breaker at engine speed dial 6 for minimum 10 minutes after the breaker is
H. During the warm up procedure, the operator should check for consistent BPM and oil
leakage.
45
I. Operate the breaker based on the procedures above for 1 day after long term storage.
Breaker can be operated normally thereafter.
⚫ Expected technical concerns for the long term storage
A. Oil film breakage between piston and cylinder
B. Decrease in elasticity of seals
Warning:
Sudden operation under high pressure can cause seizure due to

breakage of oil film.
46
OPERATION
2-7. 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) PREPARATION OF SAFE OPERATION
⚫ 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.
⚫ 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.
⚫ 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.
47
OPERATION
2) PRECAUTION BEFORE OPERATION
⚫ CHECK WORK SITE CONDITION

Operators should check the geological or soil condition before machine operation to prevent
any possible accident.
⚫ 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)
48
OPERATION
2-8. CORRECT OPERATION
BREAKER ROTATING WORK
The followings should be kept to prevent any serious injury or death.
- Before rotating 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.
49
OPERATION
OPERATE THE MACHINE WITH CARE
Operator should concentrate on the operating. Careless operation could lead to 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.
50
OPERATION
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.
DO NOT OPERATE THE BREAKER 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 it also could cause early damage of various joint parts of the
excavator.
51
OPERATION
PROHIBITION OF EXCAVATOR LIFTING
If operator lifts excavator using 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 ONLY FOR THE SPECIFIED WORK
If using the breaker for crane work or suspending heavy objects, serious injury, an accident, or death may
occur.
52
OPERATION
PROHIBITION 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.
Even the bolts of breaker may be broken, the bracket damage, the tool broken.
53
OPERATION
PROHIBITION OF PUSHING OR PULLING OBJECT WITH BREAKER HOUSING
Operator should be careful in pushing or pulling object with breaker housing because it could break joint
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.
54
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.

⚫ 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)
⚫ Disassemble the breaker from the boom of excavator
⚫ Clean the exterior of the breaker
⚫ Seal with plug cap on hose end
⚫ Dismantle the tool, and apply grease to piston bottom, tool bushing, tool pin, the inside of front
head
⚫ After sufficient greasing, re-install the tool, and cover with the waterproof tarpaulin (tarp)
< WELL VENTILATED AND DRY INDOORS >
< H140 >
55
OPERATION
3-2. LONG TERM STORAGE

If the event of long term storage (longer than six months), carry out following procedures.
⚫ The breaker must be stored standing up in a vertical position. If unavoidable, store it horizontal on
the wooden block.
⚫ 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.
◼ Standing up
⚫ The breaker must be stored in a storage-stand
⚫ Clean the exterior of the breaker, and check out each part for defects
⚫ Dismantle the Tool, and apply grease to piston bottom, tool bushing, tool pin, inside the front
head
⚫ Remove the gas pressure from back head
⚫ Load the hammer by letting the tool or fixture on the stand push the piston up into the cylinder.
⚫ Seal the high-pressure supplying port with plug
⚫ Cover with the waterproof tarpaulin (tarp)
※ “A” = Height of stands
MODEL “A”(mm)
H140 796.5
56
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.
⚫ Before starting operation, remove the tool and check the corrosion on the piston bottom.
⚫ In the event of horizontal storage for a long period, check deformation of seals on hammer before
using.
⚫ Warm up the hammer at idle for 10~15 minutes without nitrogen gas in the back head.
⚫ Check the regularity of hammer frequency during warming up.
⚫ Check the hose and pipe line for oil leakage and damage.
⚫ When all are in good working order, charge the gas in the back head, and then start operation.
57
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 Cause Correction

1. No blowing
(1) No hydraulic oil supplied to (a) Failure of hose and pipe (a) Inspection, repair, or
breaker. replacement of piping system
(b) Stop valve is closed. (b) Open stop valve.
(c) Failure of operation valve (c) Inspection, repair, or
system replacement of valves
(d) Insufficient hydraulic oil (d) Add oil into the oil tank until
specified level.
(2) Sufficient hydraulic oil supplied (e) Failure inside the breaker (e) Ask the dealer for inspection
to breaker. and maintenance.
(f) Nitrogen gas pressure at the (f) Adjust the nitrogen gas
back head is excessively high. pressure.
2. Blowing, but weak breaking

power.
(1) Insufficient hydraulic oil (a) Failure of hose and pipe (a) Inspection, repair or
supplied to breaker. • Clogged piping system replacement of piping system
• Oil leakage
(b) Failure of operation valve (b) Inspection, repair, or

system replacement of operation valve
• Deformed pedal system
• Deformed control cable
• Galling control valve
(c) Insufficient hydraulic oil (c) Add oil into the oil tank until
specified level.
(d) Contamination and (d) After cleaning the tank, change

deterioration of hydraulic oil the oil completely.
(e) Pump out of order (e) Ask the excavator dealer for
maintenance.
(f) Drop of the relief valve pressure (f) Ask the excavator dealer for
maintenance.
58
OPERATION
Situation Cause Correction

(2) Sufficient hydraulic oil supplied to (f) Failure of the inside of cylinder (f) Ask your dealer for an
breaker. • Entry of foreign particles inspection.
(g) Drop in nitrogen gas pressure

(3) Weak impact power and excessive at the back head (g) Adjust the nitrogen gas
hose vibration. pressure.
(h) The cylinder adjuster is kept
open. (h) The cylinder adjuster of
blows.
3. Weak impact power and excessive

hose vibration. (a) The accumulator of the breaker (a) Ask the dealer for inspection
body is defective. and maintenance.
• Gas leakage • Fill the gas or replace the
• Breakage of membrane membrane
(b) Drop in nitrogen gas pressure (b) Adjust the nitrogen gas
at the back head. pressure.
(c) The cylinder adjuster is kept (c) The cylinder adjuster of

open. blows.
4. Oil leakage from the front head or

bottom of tool increases. (a) Abrasion of the cylinder seal (a) Ask the dealer for an
inspection.
• Check if the normal
lubricating grease flows out
of the tool or if hydraulic oil
flows out.
5. Cylinder adjuster
(a) Damage of O-ring or backup (a) Replace the of O-ring or
(1) Oil leakage from cylinder adjuster
ring from the adjust bolts backup ring
area
(b) Damage of threads of adjust (b) Replace the cylinder adjust
(2) Sudden increase of piston stroke
bolt bolt
59
OPERATION
5. OPERATING PRINCIPLE
STEP 1
1. Before oil flow is supplied at the stage,

operating valve is at the lower 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 oil flow is supplied, the oil flow

at the bottom of cylinder will make piston go 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 compresses.
60
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. As oil pressure in the valve A3, A5 and converts

into high pressure, A3, A5 and A4 become high
pressure. However, considering the connection
of the area of the valve.
3. A3 > A4, so valve having a force of an upward

movement rises 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
61
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
cylinder converts into high pressure.
2. Even though the bottom and the top of the cylinder

are high pressure, piston is on the downward
movement because area on the upper side of the
piston is bigger than the one on the lower 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, another
hydraulic oil supplied from pump and hydraulic oil
that is filling up when accumulator is in expansion
connect to the pressure chamber of the valve.
And they flow through the upper of the cylinder.
4. Accumulator is for preventing the upper side of the

cylinder from a pressure drop as it fills up a
vacancy of the upper of the cylinder, occurred by
piston drop at high speed, with hydraulic oil.
62
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 valve is
turning into low pressure.
2. Keep in your mind that valve connector for

high pressure is always high pressure, so the
valve is going down.
3. This process occurs in very short time.
4. As valve starts to go down at the same time.
63
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
H140 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
64
OPERATION
PROCEDURES FOR SUPPLIED AIR PRESSURE SETTING
WARNING
Do not supply the compressed air 6bar (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 hammer
before it is submerged in the water. Maintain the air pressure with 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.
65
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.
Air compressor must be running before putting hammer in the water.
Do not shut off air while hammer is under water. Damage to hammer and contamination of carrier
hydraulic circuit may happen.
(1) At the starting the hammer which has been stored for a long term, place the hammer vertical and
take out the hydraulic oil from a clearance between the tool bushing.
(2) Supply the compressed air into the hammer.
(3) Start to operate the hammer after the compressor pressure reaches 6bar (87psi).
(4) Stop the hammer immediately and determine the cause if the air supply stopped during operation.
In case of it, there will be no bubbles.
(5) Lay the hammer in the water as <FIG 3>, and check the bubbling point.
(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.
(7) Grease the tool more than ordinary lubrication because the grease is blown off by supplied air.
< FIG 3 >
66
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 during
supplying the air in order to drain water completely.
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 above,
then place the hammer as <FIG 4>.
B) Then pour one liter of hydraulic oil into a clearance between the tool and tool bushing <FIG 5>.
C) Cover the tool and the tool bushing with a waterproof tarpaulin (tarp).
67
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 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
68
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 62). 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.
69
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.
70
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 INSPECTION
Regular equipment inspection is required to prevent equipment from breaking.

Inspection result should be recorded for future maintenance.
FOLLOWING MAINTENANCE SAFE GUIDELINE
Operator should follow the safe guideline related regular inspection and maintenance. 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 serious injury or death. Operator
should always wear eye protection goggle, safety hat, safety shoes & gloves, earplugs for hearing
protection.
Using hammer or grinder, you should wear goggle and safety mask to protect yourself from flying
debris.
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
71
MAINTENANCE
LIGHTING AND LANTERN
Improper lighting creates narrow vision and may cause serious injury. Work site should always be
bright. 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.
72
MAINTENANCE
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 SOLUTION
POINT
• Replace the damaged bolts

• Supply the bolt when missing
• Accumulator bolts Looseness
• Tighten to the specified torque
• Side Rod bolts Missing
BOLT • Top bracket bolts Damage
Notice: When one side rod is damaged,
• Housing joint bolts Falling-off
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
73
MAINTENANCE
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 hydraulic
Oil leakage
SEAL • Cylinder seal
Gas leakage
oil, contact your dealer
• 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
TOOL • Various kinds of tool
Deformed,
procedure
• If the degree of damage is not heavy,
Broken
repair with a grinder and reuse.If not,
replace with a new tool
• Before greasing, down pressure must

be applied to push the tool up into the
• Grease port on the breaker
GREASE front head
Greasing
• 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 its
HYDRAULIC 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.
74
MAINTENANCE
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 BRACKET
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 tighten
• Check the looseness of joint
PIPE • Mounting bolt looseness • Check the torque

VALIDATE
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
SETTING opened and closed
• Oil leakage
• Visual inspection
• Check the damage
• Remove the particles
• Check the materials

• Check the lever • Lever must operate normally
75
MAINTENANCE
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)
76
MAINTENANCE
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.
77
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
78
MAINTENANCE
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℉)
79
MAINTENANCE
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.
80
MAINTENANCE
5. NITROGEN GAS CHARGING
5-1. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF BACK HEAD
WARNING
⚫ Use Nitrogen Gas Only.
The nitrogen gas is only injected into the back head and the accumulator for the hammer operation
⚫ Charge Back Head After Completion of Powercell Assembly.
While in gas charging operation into the back head, the gas pressure may push the piston and the tool
out consequently. Do not stand in front of the tool during the gas charging process. Do not charge the
back head before the powercell assembly is conducted. The inlet and outlet ports must be plugged to
prevent the oil spraying..
1) Install the pressure gauge (25bar) on the

charging block.
2) Turn the handle of the charging block clockwise

to close the exhaust valve.
81
3) Connect one end of the gas hose to the nitrogen
gas tank.
4) Connect the other end of the gas hose to the

charging block.
5) Remove the plug from the charging valve on the

powercell.
82
6) Install the charging block to the charging valve of
the back head (Ensure that an O-ring is installed
on the charging block).
7) Slowly turn the handle of the nitrogen gas tank

anticlockwise to charge nitrogen gas in the back
head (Ensure that the exhaust valve of the
charging block is fully-closed).
Caution : Sudden increase in pressure over the

measurement tolerance may damage
the gauge. When the gauge exceeds
the measurement tolerance, close the
handle immediately.
8) Shut off the nitrogen gas tank by turning the

handle clockwise. Press the switch of the
charging block to check the gas pressure inside
the back head (The gas pressure shown while
pressing the switch is the actual gas pressure
level inside the back head).
83
9) After checking the gas pressure in step 8) is set
to 5-10 bar more than the specified pressure level
in the specification, then slowly open the exhaust
valve while continuously pressing on the switch
to discharge excess nitrogen gas until the gas
pressure drops down to the specified pressure
level in the specification.
84
10) When the gas pressure is set to the specified
pressure level, release the switch and open the
exhaust valve to discharge the nitrogen gas
from the gas hose.
11) Remove the charging block from the charging

valve.
12) Check for the gas leakage using soap bubbles

around the charging valve.
13) Install the plug.
85
MAINTENANCE
5-2. SPECIFIED NITROGEN GAS PRESSURE FOR BACK HEAD
Temperature
H140
(Breaker body)
℃ ℉ bar psi
-20±5 -4±9℉ 8.2 75.4
-10±5 14±9℉ 8.4 78.3
0±5 32±9℉ 8.6 81.2
10±5 50±9℉ 8.8 84.1
20±5 68±9℉ 9.0 87.0
30±5 86±9℉ 9.2 89.9
40±5 104±9℉ 9.4 92.8
86
MAINTENANCE
5-3. INSTRUCTIONS FOR GAS PRESSURE INSPECTION

charging block.
2) Turn the handle of the charging block clockwise to

close the exhaust valve

gas tank.

charging block.
87
5) Remove the Hex. head bolt from the accumulator.
6) After removing the Hex. head bolt, then slowly

remove the gas charging cap from the gas
charging bolt.
Danger : When the Hex. head bolt remains locked

and the gas charging bolt is unscrewed
together with the gas charging cap
during removing of the gas charging cap,
the gas charging bolt with the gas
charging cap may pop out due to
pressurized nitrogen gas in the
accumulator. Make sure to completely
remove the Hex. head bolt in step 5)
before performing step 6).
Caution : When removing, check whether the gas

charging bolt is unscrewed together
with the gas charging cap. If it is,
release all nitrogen through the Hex
head bolt hole and replace both the gas
charging bolt and the gas charging cap
for proper operation and safety. Refer
to “Instructions for Nitrogen Gas
Charging” to charge up the
accumulator after parts replacement.
88
7) Install the charging block to the gas charging valve
of the accumulator (Ensure that an O-ring is
installed on the charging block).
8) Loosen the gas charging bolt by turning it half a

turn anticlockwise using an allen wrench (hex key)
of size 5mm.
Danger : The gas charging bolt may pop out when

it is loosened too much. Do not turn it
more than 2 revolutions.
9) Measure the gas pressure in the accumulator by

checking the gauge level..
89
MAINTENANCE
5-4. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF ACCUMULATOR

charging block.
2) Turn the handle of the charging block clockwise to

close the exhaust valve

gas tank.
90
charging block.
5) Remove the Hex. head bolt from the accumulator.
91
6) After removing the Hex. head bolt, then slowly
remove the gas charging cap from the gas charging
bolt.
Danger : When the Hex. head bolt remains locked

and the gas charging bolt is unscrewed
together with the gas charging cap during
removing of the gas charging cap, the
gas charging bolt with the gas charging
cap may pop out due to pressurized
nitrogen gas in the accumulator. Make
sure to completely remove the Hex. head
bolt in step 5) before performing step 6).
Caution : When removing, check whether the gas

charging bolt is unscrewed together
with the gas charging cap. If it is,
release all nitrogen through the Hex
head bolt hole and replace both the gas
charging bolt and the gas charging cap
for proper operation and safety. Refer to
“Instructions for Nitrogen Gas
Charging” to charge up the accumulator
after parts replacement.
7) Install the charging block to the gas charging valve

of the accumulator (Ensure that an O-ring is
installed on the charging block).
92
8) Loosen the gas charging bolt by turning it half a
turn anticlockwise using an allen wrench (hex key)
of size 5mm.
Danger : The gas charging bolt may pop out when

it is loosened too much. Do not turn it
more than 2 revolutions.
9) Slowly turn the handle of the nitrogen gas tank

anticlockwise to charge nitrogen gas in the
accumulator (Ensure that the exhaust valve of the
charging block is fully-closed).
Caution : Sudden increase in pressure over the

measurement tolerance may damage
the gauge. When the gauge exceeds
the measurement tolerance, close the
handle immediately.
10) When the gas pressure indicated on the pressure

gauge is set to 5-10 bar more than the specified
pressure level in the specification. Shut off the
nitrogen gas tank by turning the handle clockwise
(The gas pressure shown after shutting off the
nitrogen gas tank is the gas pressure level inside
the accumulator).
93
11) After closing the handle, then slowly open the
exhaust valve while the gas charging bolt is still
loosened to discharge excess nitrogen gas until the
gas pressure drops down to the specified pressure
level in the specification.
12) When the gas pressure is set to the specified

pressure level, tighten the gas charging bolt by
turning it clockwise and open the exhaust valve to
discharge the nitrogen gas from the gas hose.
Remove the charging block from the gas charging
valve.
94
13) Check for gas leakage using soap bubbles around
the gas charging valve and gas charging bolt.
14) Install the Hex. head bolt and the gas charging cap.
(Ensure that an O-ring is installed on the gas
charging cap).
95
MAINTENANCE
5-5. SPECIFIED NITROGEN GAS PRESSURE FOR ACCUMULATOR
Temperature
H140
(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
96
MAINTENANCE
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 after grinding the worn parts of front head and tool pin. Insert a new tool pin after
grinding the scuffed parts of front head in use.
97
MAINTENANCE
< WEAR LIMIT >
< H140 >
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
THRUST RING UPPER BUSHING
MODEL
A (New Part) B (Wear limit) C ( New Part) D (Wear limit)
H140 101(mm) 104(mm) 153(∅) 159(∅)
98
MAINTENANCE
< WEAR LIMIT OF ③TOOL PIN >
< H140 >

UNIT : mm
MODEL E (New Part) F (New Part) G (Wear Limit) H (Wear Limit) I

1.5
H140 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) K (Wear Limit) L (New Part) M (Wear Limit)
H140 30(∅) 28(∅) 153(∅) 159(∅)
99
MAINTENANCE
7. T ORQU E
7-1. TORQUE (OPEN TYPE)
HOUSING
6
7
4
1
2
3
8
5
< H140 >

*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
H140 1,500 3,050 RD52x3.175 1,200 2,300 M36x4.0
100
MAINTENANCE
HAMMER
< H140 >
SIDE ROD NUT Ⓐ HEX.SOCKET BOLTⒷ
MODEL TORQUE
(N.m) TORQUE
SPECIFICATION SPECIFICATION
(N.m)
1st 2nd
H140 2,150 4,250 HEX.85x85 200 M14x2.0x40
101
MAINTENANCE
VALVE COVER ( UPPER )
VALVE COVER ( LOWER )
< H140 >
VALVE BLOCK VALVE BLOCK

VALVE BLOCK BOLT Ⓐ COVER BOLT Ⓑ COVER BOLT Ⓒ
MODEL
TORQUE TORQUE TORQUE
SPECIFICATION SPECIFICATION SPECIFICATION
(N.m) (N.m) (N.m)
H140 500 M20x2.5x70 500 M20x1.5x60 500 M20x1.5x45
102
MAINTENANCE
< H140 >
ACCUMULATOR ACCUMULATOR
COVER BOLT Ⓐ BOTTOM BOLT Ⓑ
MODEL
TORQUE TORQUE
SPECIFICATION SPECIFICATION
(N.m) (N.m)
H140 550 M20x1.5x60 950 M24x3.0x70
103
MAINTENANCE
8. REPAIR & REPLACEMENT
8-1-1. OPEN HOUSING
< H140 >
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.
104
MAINTENANCE
8. REPAIR & REPLACEMENT

8-1-2. BOX HOUSING
< H140 >
1) Lay down the housing horizontal on the ground

2) Install the wearing plates (1)
3) Place the housing upright
3) Install the base buffer (3) and the powercell
4) Place the bushings on the hammer and install the pin (4)
5) Install the stopper (5)
6) Put the top buffer (6) and top wearing plates (7) and top plate (9)
7) Place the top plate (8) and install bolts and nuts (9, 10)
8) Install the cover plates (13, 16) by using bolts and washers (14, 15, 17, 18)
9) Install rubbers
105
MAINTENANCE
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 die.
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.
< H140 >
< 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.
106
MAINTENANCE
< B-SERIES >
SIDE ROD NUT (UPPER)

MODEL
SPECIFICATION
H140 HEX.85 x 65
107
MAINTENANCE
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.
< H140 >
BACK HEAD LOWER PISTON

SEALING SYSTEM SEALS - CYLINDER
108
MAINTENANCE
⚫ 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.
⚫ 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.
⚫ 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
⚫ Grip the seals so that they form a "U-

shape".
⚫ Push the U-shaped seal into the grooves
to be fully seated.
109
MAINTENANCE
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.
- H140 : 1 mm
110
MAINTENANCE
8-5. TOOL & TOOL BUSHING
< H140 >
MODEL EYE BOLT “A”
H140 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 snap ring Ⓙ, rubber plug Ⓚ, and upper bushing pin Ⓛ to remove upper bushing Ⓜ.
111
MAINTENANCE
1) Assembly of Upper bushing
a. Turn front head upside down.

b. Insert the upper bushing into the front
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
the upper bushing,
Note
Heating up of upper bushing area to 100
degrees Celsius may be required for
assembly of upper bushing.
112
MAINTENANCE
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 go the front head and tighten
it with Lower nuts.
e. Operate the hand pump continuously to
push the puller down until upper bushing
fall down to the ground.
113
MAINTENANCE
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).
114
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.
115
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.
116
MAINTENANCE
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.
117
MAINTENANCE
Pull out the piston slowly.
Remove the cylinder from front head.
118
MAINTENANCE
10. ADJUSTMENT
10-1. CYLINDER ADJUSTER
One of the most potentially damaging events in a breaker's life is blank firing. The "blank firing", that is,
when the piston slams down to the bottom of its stroke without contacting the tool, the energy which
should have been transmitted to the workpiece is absorbed in the breaker body. This can cause so
much damage to the inside of a breaker. To lessen the effect of blank firing, Auto Shut-Off (ASO)
system is available.
The operator can selectively adjust On & Off Modes of Auto Shut-Off function according to the given
working condition.
The Auto Shut-Off PLUG is on the right side of the cylinder.
In ASO On Mode, the hammer automatically stops when the tool tip is no longer in contact with the
material. It reveals its benefits in a work condition where visibility is poor(e.g. underwater). This reduces
the strain on breaker, and ultimately increases the hammer lifespan.
In ASO Off Mode, the breaker starts without load applied to the tool, thus simplifying handling by saving
time to position the breaker. This provides great productivity through increased efficiency of hammer
operation.
Standard factory setting is ASO On mode which preventing no-load stroke.
Adjusting of the modes
(1) Switching to ASO Off Mode (2) Switching to ASO On Mode
① Untighten ASO Plug. ① Untighten ASO Plug.

② Install ASO PIN(You can find ASO Pin in the ② Remove ASO PIN (Keep the ASO PIN well for
toolbox). reuse).
③ Retighten ASO Plug. ③ Retighten ASO Plug.
119
TOOL FAILURE
ANALYSIS
120
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.
121
TOOL TROUBLESHOOTING
Failure dented by imperfect blow due to

NOT WARRANTY
excessive wear of tool bushing.
Failure due to blank firing or heavy wear of

NOT WARRANTY
tool pin groove.
Failure due to excessive bending, seizing

in tool bushing, prying heavy objects NOT WARRANTY
(Typical failure)
Mushrooming of fast wear of tool tip

caused by blowing on the same spot at a
NOT WARRANTY
time for a long time, levering, and improper
firing.
122
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
123
1-2. TOOL FAILURE REJECTED UNDER WARRANTY
1) FATIGUE FAILURE (NOT WARRANTY)

This pattern is typical failure caused by 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 or repair damaged parts.
124
2) EXCESSIVE BENDING (NOT 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 formation.
125
3) SEIZING IN TOOL BUSHING (NOT WARRANTY)
Strong side load and striking at the same time can cause damage tool and tool bushing surface. This
pattern is caused by wrong working angle, wrong or insufficient lubrication or both.
Failure generally occurs in front tool bushing area.
126
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)
127
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.
128
REUSABILITY GUIDELINE
FOR PISTON & CYLINDER
129
1. POTENTIAL CAUSES OF PISTON & CYLINDER SCRATCHES
NO. ITEM DESCRIPTION CORRECTIVE DIRECTION
Galling caused by misalignment

Poor replacement
between piston and tool due to Consumable parts maintenance in
1 of consumable
heavy wear of tool bushing and time.
parts in proper time
upper bushing.
Galling caused by lack of oil film

Insufficient warm
2 formation due to insufficient warm Full warm up before operation.
up
up operation.
Follow the oil & filter change

Hydraulic oil Galling caused by foreign particles
3 intervals as recommended by
contamination in hydraulic oil.
machine manufacturer.
Poor quality hydraulic oil causes

Follow hydraulic oil change
Poor quality poor oil film formation and
4 interval as recommended by
hydraulic oil corrosion on the parts can cause
machine manufacturer.
galling on the piston.
Premature wear of tool bushing

and upper bushing caused by lack
Improper grease of grease and galling caused by Keep the proper grease injection
5
injection misalignment between piston and method.
tool due to heavy wear of tool
bushing and upper bushing
Galling due to foreign particles in

Take necessary contamination
the hydraulic hoses & piping lines
6 Foreign particles control measures eg. capping of
during installation or repair of the
hydraulic lines upon removal.
piping lines at job site.
130
2. RESUABILITY GUIDELINE FOR PISTON
2-1. GENERAL UNDERSTANDING OF PISTON
1) The piston is the main part which works in the cylinder. Thus, sliding friction occurs between inner
circumferential surface of the cylinder and outer circumferential surface of the piston.
2) Since the piston moves up & down with the contact of the seal on the cylinder, the contact areas at upper and
lower side of the piston has some glossy reflection due to the result of the contact.
3) For inspection of the piston, the hammer should be disassembled while it is standing upright to avoid
unexpected scratches.
4) After disassembly of the hammer, a visual inspection of the piston surface under any illumination giving
sufficient level of luminous intensity for detailed observation of markings on the piston surface needs to be
conducted after cleaning the piston.
5) When scratches are found, please refer to the pictorial guidelines to determine reusability. If it is determined
to be reusable, grinding is conducted to eliminate or minimize the surface scratches of the piston.
6) The reuse of the piston is only allowed when it satisfies the wear limit in the dimensional guideline.
131
2-2. ACCEPTABLE CASES FOR PISTON REUSE
1) CASE 1
OBSERVED MARKINGS MAIN REASON(S) / UNDERSTANDING(S)
Zigzag or seesaw pattern derived from

superfinishing is observed.
GUIDELINE TIP(S)
It is normal condition. The piston can be reused

without any extra processing.
132
2) CASE 2
Seal contact markings. It can be observed after

certain period of contact with the seal.
GUIDELINE TIP(S)
Acceptable condition to reuse and no extra

processing is required.
3) CASE 3
These vertical direction of the scratches might

occur due to a momentary piston eccentricity in
the cylinder. Occasionally, this kind of scratch
pattern is found at the beginning of operation
such as warm up operation.
GUIDELINE TIP(S)
Reusable after grinding based on the repair

guideline and checking whether the wear limit in
the dimensional guideline is satisfied.
133
4) CASE 4
Vertical direction of scratches.
GUIDELINE TIP(S)
Reusable after grinding based on the repair

guideline and checking whether the wear limit in
the dimensional guideline is satisfied.
134
2-3. UNACCEPTABLE CASES FOR PISTON REUSE
1) CASE 1
Rust on the surface is generated due to

inappropriate and incorrect storage which do not
comply with suggested storage guideline in the
manual.
GUIDELINE TIP(S)
Not allowed to reuse.
135
2) CASE 2
Serious galling.
GUIDELINE TIP(S)
3) CASE 3
Continuous use of the piston with light level of

scratches results in a crack of the piston along
horizontal direction.
GUIDELINE TIP(S)
136
4) CASE 4
Continuous use of the piston with light level of

scratches results in cracks of the piston along
vertical direction.
GUIDELINE TIP(S)
5) CASE 5
PATTERN OF SCRATCHES MAIN REASON(S) / UNDERSTANDING(S)
Groove was found on the piston at seal

contacting area. Normally occurred in case of
defective raw material of the piston.
GUIDELINE TIP(S)
137
3. RESUABILITY GUIDELINE FOR CYLINDER
3-1. GENERAL UNDERSTANDING OF CYLINDER
1) The cylinder guides the piston movements with an upper seal of the seal housing mounted in the cylinder and
a lower seal of the cylinder. The cylinder is normally assembled with a gap to the piston so that hydraulic oil
with high pressure does not leak out and small amount of hydraulic oil film is formed therein.
2) In order to investigate the cylinder, the piston has to be removed from the cylinder completely. During the
disassembly of the piston, the hammer should be disassembled while it is standing upright to avoid unexpected
scratches.
3) After disassembly of the hammer, a visual inspection of the cylinder surface under any illumination giving
sufficient level of luminous intensity for detailed observation of markings on the cylinder surface needs to be
conducted after cleaning the cylinder. Meanwhile, once some scratches are found on the piston, there is high
possibility that other scratches can be found in the cylinder.
4) When scratches are found, please refer to the pictorial guidelines to determine reusability. If it is determined
to be reusable, grinding is conducted to eliminate or minimize the surface scratches of the cylinder.
5) The reuse of the cylinder is only allowed when it satisfies the wear limit in the dimensional guideline.
138
3-2. ACCEPTABLE CASES FOR CYLINDER REUSE
1) CASE 1
Normal condition.
GUIDELINE TIP(S)
Acceptable condition to reuse and no extra

processing is required.
139
2) CASE 2
Light scratches observed
GUIDELINE TIP(S)
Allowed to reuse after grinding based on the

repair guideline and checking whether the wear
limit in the dimensional guideline is satisfied.
3) CASE 3
Light scratches observed
GUIDELINE TIP(S)

140
4) CASE 4
Galling observed on the cylinder surface but the

depth is not serious.
GUIDELINE TIP(S)

141
3-3. UNACCEPTABLE CASES FOR CYLINDER REUSE
1) CASE 1
Deep pittings due to external particles are

observed.
GUIDELINE TIP(S)
142
2) CASE 2
Serious galling.
GUIDELINE TIP(S)
3) CASE 3
Serious galling.
GUIDELINE TIP(S)
143
4) CASE 4
Serious galling.
GUIDELINE TIP(S)
144
4. REPAIR GUIDELINE FOR PISTON & CYLINDER REUSE
1) OPERATIONAL GUIDELINE OF USING BUFFING GRINDER FOR PISTON
⚫ Clean the piston surface before proceeding.
⚫ Grinding and buffing should be conducted along the circumference and not along the length of the piston as
shown in the above picture. Use a rotary table to facilitate repairs.
⚫ The grit of the hand grinder or sandpaper needs to be between #1000 and #2000.
⚫ After the scratches found are completely eliminated, carefully measure to check whether it is within
tolerance.
⚫ Once the repair service is successfully done, clean the piston surface again before reassembly of the piston.
145
2) OPERATIONAL GUIDELINE OF USING BUFFING GRINDER FOR CYLINDER
⚫ Clean the cylinder surface before proceeding.
⚫ Grinding and buffing should be conducted along the circumference and not along the length of the cylinder
as shown in the above picture.
⚫ After the grinding, smooth the sharpened edges of inner circumferential grooves.
⚫ Carefully measure to check whether it is within tolerance.
⚫ Once the repair service is successfully done, clean the piston surface again before reassembly of the
cylinder.
146
5. RECOMMENDED MEASUREMENT GAUGES FOR REPAIR SERVICE
The recommended gauges are attached as reference.
1) PISTON MEASUREMENT : MICROMETER
GAUGE EXAMPLE OF MEASUREMENT
2) CYLINDER MEASUREMENT : DIAL BORE GAUGE
GAUGE EXAMPLE OF MEASUREMENT
147
6. DIMENSIONAL GUIDELINE FOR WEAR LIMIT OF PISTON & CYLINDER REUSE
Max Max Max

A D B E C F
MODEL Clearance Clearance Clearance
(min) (max) (min) (max) (min) (max)
A-D B-E C-F
WEAR
H140 159.92 160.03 0.11 172.42 172.53 0.11 154.92 155.26 0.34
LIMIT
1) The guideline should be applied based on Max clearance level. If the item has measured dimension over
tolerance range, it can be reused when the clearance is within the specified Max clearance. For example, when
A is 159.90 and D is 160.00, the clearance A-D is 0.10 and they can be reused although A is beyond the
tolerance.
2) The depth of the galling/scratches is more of a concern than the length of the galling/scratches.
148
7. REASSEMBLY GUIDELINE
Reassembly Service Procedure

1) All parts to be reassembled should satisfy the wear limits in the dimensional guideline after the repair
service.
2) All parts should be cleaned before reassembly.
3) The reassembly should be conducted in a clean environment with the hammer upright.
4) Refer to reassembly procedure within this manual.
149
WARRANTY
Coverage CAT WORK TOOLS WARRANTY (Worldwide)
SELF5453
NOTE
Hammer must be SCORED by dealer for warranty
150

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H140GC &amp; H140GCS Hydraulic Breakers

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GESR0853-01

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

7. TORQUE ........................................................................................................................................................................................ 100

TOOL FAILURE ANALYSIS

REUSABILITY GUIDELINE FOR PISTON & CYLINDER

WARRANTY .......................................................................................................................................................................................... 150

Safety Alert Symbol

Safety alert symbols are as follows:

DEFINITION & APPLICATION

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

HYDRAULIC BREAKER is widely used for

< H140 >

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

UNDERSTANDING OF OPERATION MANUAL

OPERATION MANUAL & WARNING

OPERATION MANUAL & WARNING OBSERVATION

WEARING SAFETY GEAR

Operator should wear safety hat and shoes.

PREVENTION OF FIRE AND ACCIDENT

OPERATIONAL WORK SITE RULES

2. PRECAUTION BEFORE OPERATION

HEAD GUARD ATTACHMENT TO EXCAVATOR

WINDOW SAFETY GUARD INSTRUCTION

CHECK WORK SITE CONDITION

EQUIPMENT CHECK BEFORE MACHINE OPERATION

The following parts should be checked:

- Leakage of the hydraulic system or other functioning parts

CHECK THE QUICK COUPLER ATTACHMENT STATUS

HYDRAULIC HOSE CHECK BEFORE OPERATION

CORRECT OIL FLOW AND PRESSURE SETTING

3. PRECAUTION DURING OPERATION

SECURE BRIGHT OPERATING SITE

SUPERVISOR INSTRUCTION OBSERVATION

OPERATION LEVER PEDAL AND SWITCH CHECK

BE AWARE OF OPERATION AT THE SLOPE.

ELECTRIC SHOCK WARNING

CHECK DIRECTION OF TRAMMING MOTOR

OPERATE CAREFULLY WHEN ROTATING EXCAVATOR

BE CAREFUL OF UNDERGROUND UTILITIES

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

BE CAREFUL OF SOIL PILE

DO NOT OPERATE ON CLIFF

WARNING FOR FALLING ROCKS

WARNING FOR FLYING & FALLEN ROCKS

IMMEDIATE ENGINE STOP WHEN OIL LEAKAGE IS FOUND

USE THE BREAKER ONLY FOR THE SPECIFIED WORK

Operator should be careful when operating indoors or in narrow places.

4. PRECAUTION AFTER OPERATION

CAUTION WHEN RE-FUELING

KEEPING SAFE FOR EXCAVATOR

- Park excavator on flat and solid ground.

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

1-1. PART NAME & STRUCTURE

< H140 >

1-2. GENERAL SPECIFICATION

DESCRIPTION CB & CB2 Linkage DB Linkage TB Linkage

IMPACT RATE bpm 250~550

OIL FLOW l/min 180~220

BACK PRESSURE bar 10

VISCOSITY cSt 1000~15

※ Working weight includes moil tool and top bracket

CB & CB2 Linkage DB Linkage TB Linkage

IMPACT RATE bpm 250~550

OIL FLOW l/min 180~220

H140GC & H140GCS Hydraulic Breakers

H140GC & H140GCS Hydraulic Breakers