Brokk Manual

Part. No: 3136 8014 96-H GB

Translation of the original instructions

Brokk AB • PO Box 730 • SE-931 27 Skellefteå • Sweden

Tel: +46 910 711 800 • Fax: +46 910 711 811
E-mail: info@brokk.com • www.brokk.com
Id: TD-000027-H
Status: Approved
1-TS-002355-A
 Contents
Introduction 5 Handling 35
Foreword 5 Areas of use 35
Modifications 5 The machine is intended for: 35
Manufacturer's conditions 5 The machine is NOT intended for: 35
Guarantee conditions 6 Ergonomics 36
Safety instructions 7 Regulations for environmentally ­unfriendly waste 37
General 7 Affecting the operational reliability of the machine 38
Warning levels 7 Regular service 38
If an accident has occurred 7 The machine's working environment 39
Supervisors and operators 8 Transporting and lifting 41
Protective equipment 9 Loading and unloading using a ramp 41
Machine risk zone 10 Transportation 42
Risk factors during operations 11 Lifting the machine 43
Lifting the machine 11 Working in hazardous operating zones 44
Transporting the machine 11 Working near edges 44
Work site 12 Working and movement on uneven and inclined
Electrical safety 13 surfaces 45
Radio 13 When working with pipes and cables 46
Diesel powered machine 14 Operating instructions 47
Before work 14 Control unit 47
While working 15 Safety when operating 47
Operating 17 Positioning in relation to the machine 48
After working 18 Operating the undercarriage of the machine 49
Risk factors during service and maintenance 19 Operating the upper section of the machine 50
Description 23 Starting and stopping 53
Pre work inspection 53
Machine construction 23
Connect the electrically driven machine 53
Drive 23
Start the machine 53
Outriggers 23
Post work inspection 54
Swivel function 24
Towing 54
Arm system 24
Extra equipment 24 Diesel 55
Tools 24 General 55
Battery 55
System description 25
Fuel 55
Electric system 25
Control system 25 Mechanical settings 56
Hydraulic system 26 Cleaning the machine 58
Connection to the electrical supply 27 Safety when cleaning 58
Power supply 27 Cleaning methods 58
Fuses 27 Cleaning components 59
Power supply cable 27 Before washing 60
After washing 60
Safety functions 28
Protection of personnel 28
Machine protection 30
Stickers 31
Type plate 31
Information stickers 31
Warning stickers 32
Control system 61 Service 93
Control unit 61 General 93
Battery 62 Service schedule 93
Identity code 63 Checks 93
Changing radio channels 64 Service schedule 94
Approval 64 Daily check 94
Control unit functions 65 Preparations for service and maintenance 98
Switch 65 Hydraulic fluid and lubricants 102
Starting and stopping 68 Checking instructions 103
Before starting 68 Lubrication 103
Start, remedies on the machine 68 Cracks 105
Starting the control unit 69 Securing 106
Starting the motor 69 Level check 107
Engaging the control circuit 69 Wear and damage 110
Blocking 69 Leakage 111
Stop 69 Function 112
Operating 70 Replacement 116
Operating the undercarriage 70 Other 124
Operating the caterpillar tracks and arm system 71 Welding work on the machine 125
Operating the upper section 72 Before welding 125
Changing reach 73 Recommended welding wire 126
Operating hydraulic tools 74 Advice when welding 126
Adjusting hydraulic pressure to the tool 76 Components which should not be welded 126
Adjusting 76
Electric cabinet functions 78
Tools 79
General 79
Positioning of tools 79
Hydraulic settings 79
Changing tools 80
Fixed tool mounting
Brokk 40 80
Fixed tool mounting
Brokk 50 81
Mechanical quick hitch 82
Connecting tools to the hydraulic system 83
Correct connection of tools 84
Using tools 85
General 85
Selecting tools 85
Extra equipment 87
General 87
Extra hydraulic function 87
Breaker lubrication 88
Cable drum 89
Swivel limitation 90
Forced air cooling 90
Extra work lamps 90
Earth fault relay 91
 Introduction
Foreword
Thank you for choosing a Brokk machine. We hope that it increases your work capacity.
The Brokk manual contains descriptions and instructions for all Brokk machines. Illustrations
can differ and the functions described may be different to your machine. Keep the Brokk manual
for future reference. Keep the manual safe and available for the operator in the work place.
Note before starting the machine!
It is the responsibility of the owner / employer to ensure that the operator can use the machine sa-
fely. Before starting the machine, both the supervisor and operator must have read and understood
the Brokk manual so that they understand:
The safety instructions which apply to the machine
What the machine is intended for and what it is not equipped to deal with
How to maintain, use and operate the Brokk machine
How to follow the instructions to prevent personal injury and damage to the machine.

Modifications
At the request of the owner, the machine can be modified during manufacture. These modifications
are handled as additions to the standard documentation and can be found behind the tab divider
in the folder. Always check what modifications have been made to the machine by reading the
relevant additions.
Ordering spare parts
When ordering spare parts it is extremely important to know what modifications have been made to
the machine. There may be sections in the standard documentation that are similar to the modified
machine which may cause the wrong spare part to be ordered. Always read the modified section,
which supersedes other sections, before ordering.

Manufacturer's conditions
• Brokk AB reserves the right to change the specifications and instructions of the machines wit-
hout prior warning.
• The machine must not be modified without written permission from the manufacturer. The
owner takes responsibility if the machine is modified after delivery from Brokk, and without
written permission from the manufacturer. Modification may cause new risks to the operator,
machine and surrounding area. For example these could be a reduction in rigidity or defective
protection. It is the responsibility of the owner to specify the modifications to be carried out
and to contact the machine supplier for approval before starting any such modification.

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Guarantee conditions
The following points must be met before a claim application can be requested:
• In order to be processed, a claim must be made within 14 days of the repair being completed
at the latest.
• If a damaged component can cause further damage to the machine, Brokk AB must be informed
immediately. If this is not done, the warranty does not cover any subsequent damage.
• Brokk AB is only liable for Brokk original components. The liability does not cover faults that
have occurred due to accidental damage, modifications, misuse or incorrect usage.
• Regardless of what warranty conditions may apply locally and providing no other agreements
have been made, Brokk AB’s warranty period for new standard products is 12 months from
delivery to end user, or a maximum of 1000 operating hours, whichever occurs first. If the start
date is not reported to Brokk AB, the delivery date from Brokk AB’s factory applies.
• Brokk AB’s responsibility for claims regarding failures in the design, materials or manufacture
is limited to replacement of the faulty component. In the event that specialist knowledge is re-
quired to replace a faulty component, Brokk AB will remove the old component and install the
new one. Where specialist knowledge is not required, Brokk AB has fulfilled its responsibility
when the repaired or replaced component is supplied to the purchaser.
• Brokk AB’s responsibility does not cover normal wear or degradation. Brokk AB is not liable
for faults or breakdowns caused by incorrect or defective maintenance, incorrect repairs, pro-
blems caused by dirt, water or particles in the hydraulic system or insufficient power supply.
The equipment must be used and maintained in accordance with the instructions in the Brokk
manual.
• Brokk AB’s warranty for replacement parts applies for 12 months from installation or a maxi-
mum of 18 months after delivery from the factory, whichever comes first.
• Examples of components that are not normally covered by the warranty: Cylinders, hoses,
chisels for hydraulic breakers, buckets, rubber feet, caterpillar tracks, bearings etc.
• Warranty conditions in accordance with ORGALIME S 2000.

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 Safety instructions
General
The following safety instructions cover those matters
that are absolutely essential to know and follow when
working with Brokk. Before starting the machine,
both the supervisor and operator must have read and
understood the entire Brokk manual.
If an accident has occurred
The employer has the responsibility of making a plan,
and training all operators, to deal with an accident
situation.
Do not resort to panic. React quickly and effecti-
vely to save lives and only then to prevent material
damage. Learn First Aid. You could save lives!

Warning levels Checklist for actions in event of an ac-

There are two types of warning in the manual. The
first type indicates first what the risk is and then the
situation in which it occurs. Finally it explains how
to avoid the risk. This type of warning is often supp-
lemented by a warning symbol.
The other type are warnings are graded into four
levels as shown in the example below.
Danger!
cident
• Get an overview of what has happened, if anyone
is hurt and if anyone is still in the area of the ac-
cident.
• Alert the emergency services as soon as possible.
Be prepared to supply detailed information.
• Give First Aid
• Appoint someone/several people with good local

c Indicates that an accident will

occur if the instructions are not
followed. The accident would
cause serious injury, possibly
knowledge to meet the emergency service vehicles,
unlock doors and show the way for the emergency
service personnel.
• Ensure that any casualties are accompanied to
death or severe damage to pro-
hospital
perty.
• Secure the scene of the accident
Warning! • Contact supervisors

b Indicates that an accident might

occur if the instructions are not fol-
lowed. The accident would cause
serious injury, possibly death or
• Contact subordinates
• Establish the cause of the accident
• Take action to prevent accidents
severe damage to property.
• Always inform Brokk AB of accidents whether
Caution! the machine was directly involved or not.

a Indicates that an accident might

occur if the instructions are not
followed. The accident would lead
to personal injury or damage to
property
NB! Indicates a risk of breakdown if the
instructions are not followed.

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Supervisors and operators
Responsibility
Supervisors and operators are responsible for:
• Ensuring that National and local laws, safety
regulations, precautions and other instructions
are followed when the machine is used. This
may include special protective equipment, values
for lighting and vibrations, fencing off, driver
permits etc.
• That the operator has the relevant training and
experience to carry out the work safely. This can
be achieved by experienced Brokk operators with
good judgement, guiding, training and supervising
personnel in operating and working with Brokk.
• That no one is permitted to enter the zone without
the correct training and protection. There is a risk
of accident and injury.
• That the machine is only used for the intended
uses.
• That the machine is used in a safe manner.
• That no one is permitted to enter the risk zone
or operating zone while the machine is in opera-
tion.
• That the operator is informed of the nature of
the operating zone, for example the tolerances of
the joists and the locations of load bearing walls,
cables and pipes.
• That personnel with access to the operating zone
are aware of and have access to protective equip-
ment.
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Requirements of the operator
• The operator must learn the function, characte-
ristics and limitations of the machine under safe
conditions.
• The operator must try to anticipate the risks of a
task and use this information to calculate the size
of the risk zone the machine will require. Use com-
mon sense to avoid incidents and accidents.
• The operator must stop using the machine in the
event of a hazardous situation. Ensure that the
machine cannot be used by mistake and inform
the supervisors. The machine must not be used
until the safety hazard has been removed.
• The operator must not be under the influence of
alcohol, narcotics or anything else which may
affect reaction times or judgement.
• The operator must use personal protection equip-
ment appropriate to the work.
• The operator must ensure that the machine cannot
be used by unauthorised personnel, by leaving the
control unit unattended for example.
Protective equipment
Because Brokk machines can be used in a variety of environments and for different applications, the
protective equipment must be suitable for the working conditions. The operator and supervisor must
evaluate what protective equipment is required. The following equipment is only an example.
Personal protective equipment
The following is recommended as basic protection:
• hardhat with eye protection and ear defenders
• thick overalls
• protective gloves
• safety footwear

Attention. Danger. Use personal protective equipment

Other protective equipment

• Safety harnesses and stands for control units must be used when working at height or where there is risk of
collapse. The operator and machine must be secured using separate harnesses.
• Breathing masks, gas masks or airstream helmets must be used in environments where the inhaled air is
harmful to health.
• Heat shields and appropriate protective clothing must be used when working in hot environments.
• Barriers must be used to mark out the risk zone of the machine.
• Safety equipment must be used to secure machine components during repairs or service.

Attention. Danger. Use protective equipment appropriate to the work

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Machine risk zone
The operating zone of the machine is limited by its reach. However, the risk zone can be consi-
derably larger. The size of the risk zone around the machine varies considerably depending on
the work object, the work method, the surface underfoot, the position of the arm, the angle of the
machine, the domino effect and the driving style of the operator.

Machine operating zone The risk zone varies depending on the height The risk zone varies depending
of the work object on the incline of the surface
underfoot.

Attention. Danger. Keep your distance from the machine depending on the size of the risk zone. The size of the risk zone
varies
To avoid near misses and accidents the operator must continuously define the risk zone. Before
starting a task the operator must select the method of work, analyse any possible risks and take the
relevant safety precautions by, for example, extending the sealed off area and the distance from
the barriers to the machine and work object. If the working conditions are variable the risk zone
must be continually redefined.
No one may enter the operating zone while the machine is in operation! Remain outside the
risk zone for collapses, splinters and toppling machines. The risk of toppling machines increases
the greater the incline. The risk can change during the course of operation.

Risk of collapse and splinter injury. Use personal protective equipment. Keep your distance

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Risk factors during operations
The identification and prevention of any risks and of defining the relevant risk zone, before and
during operations, is the responsibility of the operational supervisors and the operator. Experience
of working with the machine, caution and safety precautions are important for ensuring that work
is carried out without exposing personnel or equipment to risk.
Because the machines are used in many different environments and for different types of work
it is difficult to provide general guidelines or to advise of all the possible risks. The following is a
summary of possible risk factors. The aim is to introduce the supervisors and operators to a way
of thinking which anticipates risk factors so that they can identify possible risks and take any
precautions necessary to prevent injury or damage. Use the summary as a guide when analysing
the site and working method.

Lifting the machine

• Risk of dropping the machine because of incorrect lifting method or incorrect lift. Read and
follow the instructions for lifting the machine. Check that the lifting equipment and lifts used
for lifting are fault free and approved for the weight of the machine.

Risk of compression or crushing injury. Locate and attach the lifting equipment to all the lifting eyes. Keep your dis-
tance
• Risk of injury to personnel or damage to equipment while lifting. Define the risk zone. Check
that no one is within the risk zone when lifting.

Transporting the machine

• Risk that the machine, or parts of the machine, may move during transportation. Always secure
the machine when transporting on a vehicle. Read and follow the instructions for transporting
a Brokk machine. Follow any local regulations.

Attention. Danger. Secure the load in transit

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Work site
• Risk that the operator or nearby personnel may not anticipate dangers because of inadequate
lighting. Work lighting must be satisfactory and correctly positioned. Supplement the machine
lighting with free standing work lights if necessary.

Attention. Danger. Ensure that the work lighting is satisfactory

• Risk of stumbling or slipping because of unevenness, loose materials, oil, ice or something else
on the ground. Keep the operator’s workplace clean.
• Risk of collapse. Materials, the machine and personnel risk danger from collapse depending
on the conditions of the site. Inspect each site critically for ground conditions, load bearing
constructions, domino effect etc. Do not start any work until all the risks have been defined
and precautions have been taken.
• Risk of crushing. When working at heights, on roofs or platforms for example, there is a risk to
personnel at ground level. The risk zone increases with increased height. Secure the machine.
Define and seal off the risk zone at ground level.
• Risk of toppling over. When working on inclined surfaces, there is a risk to people below the
machine. The risk zone increases with increased angle. Define and seal off the risk zone.
• Risk of injury to the operator, or other personnel in the surrounding area, by hazardous sub-
stances. Electrical, gas and liquid pipelines may be concealed. Air in confined spaces or in a
pocket can quickly become harmful by pollution from gases or dust. Ensure that the airflow
is good. Check what the risks are at each work object. Consider how the risk can be avoided.
Follow local regulations for handling the relevant materials.

Risk of asphyxiation. Ensure good ventilation. Use a gas mask Risk of hazardous substances in solid or gas form. Keep your
and water flushing distance. Use protective clothing

• Risks during solo operation. Minimise the risk and increase safety by ensuring that the alarm can be raised
via a mobile telephone or other equipment.

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Electrical safety
• Risk of electric shock or burn injury from high
currents. Damaged electrical cables can cause
malfunctions in the machine and the machine
components can become conductors. The electri-
cal cabinet must not be opened when the machine
is connected to the electrical network. Certain
components in the electrical cabinet always carry
current. Check that the power cable and connector
are undamaged before connection. Always con- Risk of electric shock. Connect the machine via an earth fault
nect the machine via an earth fault relay which relay
cuts out at 30 mA.

• Risk of electric shock. Never move the machine

into water deep enough to reach and penetrate
connections, electric motors or other electrical
equipment. The machine will conduct current and
electrical equipment can be damaged. Ensure that
water does not reach the electrical equipment on
the machine.

Risk of electric shock. Ensure that water does not reach the
electrical equipment on the machine.

Radio
• Risk of stoppage. If several radio controlled ma-
chines are close to each other and are transmit-
ting radio signals on the same frequency, they
will interfere with each other. The machine with
the weaker signal will stop. Change the radio
frequencies.

Risk of stoppage. Note the risk in sites with several radio con-
trolled machines

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Diesel powered machine
Read and understand the safety precautions of the engine manufacturer before using the ma-
chine.
• Risk of poisoning by the machine exhaust gases. Air in confined spaces or in a pocket can
quickly become harmful. Ensure that there is sufficient ventilation before starting the engine.
If the machine is started indoors the exhaust pipe must be attached to an extraction fan system
to prevent exhaust gases from remaining in the room.
• Risk of fire caused by the heat of the exhaust gases. Ensure that the exhaust pipe is free from
flammable materials when the engine is running.
• Risk of fire. The fuel for the machine is a fire hazard. Ensure that there are no naked flames or
sparks in the vicinity.
• Diesel is harmful to the environment and to health. Avoid inhalation. In the event of skin contact
wash and rinse with water. Use containers and other equipment to prevent leakage.
Battery
• Risk of corrosive damage. Batteries contain sulphuric acid which is poisonous and corrosive.
Always use eye protection. Avoid contact with sulphuric acid on the skin, clothing or the ma-
chine. If you have come into contact with sulphuric acid, remove the contaminated clothing
and flush the skin generously with water for at least 15 minutes. If sulphuric acid has come
in contact with your eyes, flush with water immediately for at least 15 minutes and then seek
medical attention.
• Risk of explosion. An explosive gas is created in the battery, keep well away from sparks or
naked flames.

Before work
• Risk of damage caused by insufficient maintenance. The condition of the machine must be
checked regularly. Daily checks and regular service must be carried out according to the Brokk
instructions. Any faults must be remedied. The machine must be maintained in a condition which
does not expose the operator or other personnel to danger or accidental damage. The machine
must be kept clean. The signs and stickers must be visible and legible. Remedy any faults or
damage immediately. Avoid using the machine until the fault has been remedied.
• Risk of personal injury because personnel are within the machine’s risk zone. Define the risk
zone. Seal off the risk zone. Check that no one is within the risk zone.
• Risk of crushing when replacing tools. Follow the instructions for the machine and tool care-
fully when replacing tools.
• Risk of allergic reaction. Repeated skin contact with chemicals such as degreaser, grease, fu-
els, glycol and hydraulic fluid can cause allergic reaction. Avoid skin contact. Use protective
equipment.

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While working
Operator’s position
• Risk of injury to the operator or other personnel in the surrounding area because of incorrect
operation or a fault in the machine. Define the risk zone of the machine. No one may enter the
risk zone.

Attention. Danger. Keep your distance from the machine depending on the size of the risk zone. The size of the risk zone
varies
• Risk of injury to the operator or other personnel in the surrounding area because of the surface
giving way or the machine moving suddenly. Do not stand on control or power cables. There
is a risk of entanglement. The operator must always be independent of the control unit when
there is risk of the machine shifting suddenly. A stand must be used if the control unit is con-
nected to the machine by a cable.

Risk of personal injury, the operator must be independent of Risk of personal injury. Do not stand on control
the machine or power cables. Keep your distance

• Risk of personal injury to the operator from falling objects. Incorrect operation or an unexpected
incident can cause collapse. Never stand beneath a work object.
• Risk of crushing or damage by the machine. The machine can change position very quickly
because of external circumstances, breakdown or incorrect operation. The machine can tip
while operating on inclined surfaces. Never stand under a raised arm even if the machine is
unpowered. Never stand where there is a risk of being crushed by the machine, between the
machine and a wall or pillar for example. Define the risk zone of the machine. No one may
enter the risk zone.

Risk of compression or crushing injury. Keep your distance from the machine

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Machine stability
• The machine can tip while operating. The stability of the machine is affected by the ground
surface, by the tool in use and the distance of the tool from the machine. Stability is also af-
fected by the ability of the operator to control the machine in a safe manner. The machine must
always be positioned as level as possible and the outriggers must be fully deployed. No one
may enter the risk zone while the machine is operating.

Risk of compression or crushing injury. Outriggers must be deployed when working. Anchor the machine. Keep your distance
• The machine can tip while being moved. The narrow track gauge of the machine means that a small irregu-
larity in the ground surface can cause such a large degree of lean that the machine tips. On certain models
the track gauge can be narrowed even further for use in confined spaces. The stability of the machine is
impaired with the tracks in the inner position. In these circumstances the arm must not be swung out beyond
the outriggers/tracks. Ensure that the arm is fully folded. Drive carefully around corners and over uneven
surfaces. Move the outriggers to just above ground level. Keep your distance.
• The machine can tip in situations where the outriggers cannot be deployed. This can apply in confined
spaces, when moving or when working close to an obstacle. Note that the stability of the machine is greatly
impaired without the outriggers deployed. The operating zone is reduced which means work must be adapted
accordingly. The risk of the machine tipping increases when the arm is swung out to the side. No one may
enter the risk zone while the machine is operating.
• Risk of compression or crushing injury. The machine may start moving unexpectedly because of an inclined
surface. Anchor the machine. Stand uphill of the machine. Keep your distance.

Risk of compression or crushing injury. Outriggers must be deployed when working. Anchor the machine. Keep your distance

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Falling objects
• Risk of splinters and falling objects. When working, the materials will splinter and debris will
be scattered indiscriminately. When chipping upwards the demolished material spreads within
a radius approximately equal to the distance to the area being chipped. Keep your distance.
Use personal protective equipment.

Risk of collapse and splinter injury. Use personal protective equipment. Keep your distance
• Risk of collapse. When demolishing tile linings in kilns the machine operation directly affects
the risk of collapse. The tile lining above and to the sides of the operator can be shaken loose
some distance from the area where the chipping occurs. Keep your distance. Use personal
protective equipment.
• Risk of collapse. The operator is responsible for checking that the vibrations from the hydraulic
breaker do not cause cracking in the wrong part of the object or that stones or other material do
not loosen and cause personal injury or damage to property.

Operating
• Risk of accidental operation. Do not activate the control circuits until you are sure that the
correct machine will be operated. Always concentrate on the machine when the control circuit
is switched on. Always wait until the control circuit is switched off, preferably with the motor
stopped, before entering the risk zone of the machine.
• Risk of electric shock. Do not drive over the control or power cables when working with, or
moving the machine.

Risk of electric shock. Do not drive over the control or power cables when working with, or moving the machine

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Moving the machine
• Risk of the machine tipping or sliding when driven on inclined surfaces. Driving up or down
ramps and steps carries the risk of the machine tipping or sliding. Anchor the machine. Check
that the ramp/steps can bear the weight of the machine. Use the arm as additional support when
moving on inclined surfaces.

Risk of compression or crushing injury. Outriggers must be slightly deployed when moving. Anchor the machine. Keep
your distance
• Risk of compression injury. Always stand uphill of the machine and outside the risk zone when
driving on inclined surfaces.
• Risk of the machine tipping. The arm must be in the folded position when the outriggers are not
deployed. In certain circumstances, when moving the machine, the arm can be used to lift the
drive wheels over irregularities. Because of the risk of tipping, the arm must never be swung
or raised high. Move the outriggers to just above ground level when moving the machine over
an uneven surface.
• Risk of the machine shifting. When moving, when there is a risk of the machine shifting sud-
denly, the operator should always be independent of the control unit.

Risk of the machine shifting. When moving, the operator must always be independent of the control unit

After working
• Risk of compression injury. If a hose to a cylinder on the arm system fails, the arm system can sink rapidly.
Never stand under a raised arm. Always position the tool on the machine on the floor or ground when work
is complete.
• Risk of accidental operation. Press the safety stop button before removing the control unit or leaving the
machine.

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Risk factors during service and maintenance
Most machine accidents occur during fault-tracing, service and maintenance because personnel
must be within the risk zone to carry out the work. Personal injury can be avoided by strict aware-
ness of the risk. Carry out ”Preparations for service and maintenance”.
• Risk of personal injury. Never carry out repairs on the machine without the necessary training.
Only trained service personnel may carry out work on the electrical and hydraulic systems.
Personal protective equipment and the appropriate safety equipment to mechanically secure
machine components must be used during maintenance or service. Take great care when working
with the motor running. Always switch off the motor if possible. Do not wear loose clothing
when working near rotating components.

Risk of personal injury. Switch off the motor

• Risk of the machine starting by mistake. Position clear signs so that anyone nearby understands that main-
tenance or service is in progress. When service work does not require the machine to be started the power
supply cable must be disconnected and placed so that it cannot be connected by mistake.

Attention. Danger. Risk of the machine starting by mistake. Inform personnel that service is in progress
• Risk of electric shock. Ensure that the machine is not supplied with voltage before the cable or other com-
ponents with electrical voltage are disconnected or opened. Work with high currents must only be carried
out by authorised personnel. Disconnect the battery if the machine is equipped with a diesel engine.

Risk of electric shock. Ensure that the machine is not supplied with voltage

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• Risk of damage caused by pressurised or leaking hydraulic systems. Pipe and hose couplings
can remain pressurised despite the motor being switched off and the power cable disconnected.
It must always be assumed that a hydraulic hose is pressurised and must therefore be discon-
nected with great care. Rest the arm system against the ground. Switch off the electric motor.
Use protective equipment. Never use your hand to try to stop hydraulic fluid leaking from a hose.
High pressure streams of hydraulic fluid can penetrate the skin and cause serious injury.

Risk of personal injury. Keep your distance. Rest the arm system against the ground. Switch off the motor. Read the manual
• Risk of compression or crushing injury. When removing components of the machine there is a risk that
heavy components will be set in motion or will fall. Always mechanically secure moving components before
disconnecting screwed joints or hydraulic hoses. Use lifting equipment approved for at least 500 kg loads
to secure and lift heavy machine components.

Always mechanically secure moving components before disconnecting screwed joints or hydraulic hoses
• Risk of fire or burn injuries. A number of the machine components become very hot during operation, for
example the lighting and hydraulic fluid. Therefore, many hydraulic components heat up. Do not start any
maintenance or service work until the machine has cooled down.

Risk of fire or burn injury. Allow the machine to cool. Do not cover the lighting

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• Risk that the operator or nearby personnel may not anticipate dangers because of inadequate
lighting. Work lighting must be satisfactory and correctly positioned. Supplement the machine
lighting with free standing work lights if necessary.

Attention. Danger. Ensure that the work lighting is satisfactory

• Risk of unexpected incidents. If any of the connectors or hoses are incorrectly installed the
movements of the machine can be incorrect. Ensure that the functions operate correctly. Take
care when test driving. Be prepared to switch off the machine immediately in the event of a
fault.

Attention. Danger. Take care when test driving.

• Ensure that the service location is well ventilated when working with diesel engines. There is
a risk of carbon monoxide poisoning. Use an extractor fan.
• When working with diesel engines be aware of the risk of burns caused by hot coolant or engine
oil. If the engine is hot and the coolant reservoir is opened there is a risk that hot coolant may
spray out. When replacing the oil and the oil filter there is a risk of burns from the temperature
of the oil. Always stop the engine and allow the engine to cool down before starting work on
the engine. Use thick gloves, protective clothing and eye protection.

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 Description
Machine construction
Brokk machines can be adapted for different tasks and environments during manufacture. This is
possible because the machine is constructed from modules. By combining the different modules,
Brokk machines can be adapted for very specific tasks or for more general use. The machine can
be supplemented with additional equipment, tools and accessories. The Brokk manual describes
the functions of the most frequently used modules.
1. Arm system
2. Swivel function
3. Drive
4. Outriggers
5. Tools
6. Stand, an example of an accessory

2 1

6 3
4 5
The Brokk machine is constructed from modules. The machine can be supplemented with tools and accessories.

Drive
The caterpillar tracks are driven individually by hydraulic motors. The machine can be turned
by operating the caterpillar tracks at different speeds. If the tracks are run in opposite directions
the machine can make sharp turns. The drive motors are locked by passive brakes when the drive
function is not activated.
Most of the machine models can operate the caterpillar tracks and arm system at the same time.
The function is useful when the machine is operated in difficult terrain. The arm system can be
used to stabilise the machine or to pull the machine in the direction in which the caterpillar tracks
are moving.

Outriggers
The main task of the outriggers is to give the machine stability. Therefore, the outriggers must
always be used when working with the machine. On certain models the outriggers are designed
for other functions than just providing stability, for example, the bulldozer blade.

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Swivel function
The upper section of the machine can be fully rotational or rotation limited. Refer to the technical
data of the machine. By swivelling the upper section of the machine, work can be carried out in
several directions without moving the machine.
The swivel function of the machine must not be exposed to overloading from impermissible
heavy tools. The heavy weight Brokk machines are equipped with a swivel brake. When the swivel
function is not activated the function is braked by a passive brake.

Arm system
The arm system consists of three sections which provide good movement characteristics, long
reach and remain compact. Conical shafts minimise the risk of play. By operating cylinder 1 and
cylinder 2 at the same time, the reach of the machine can be adjusted without the machine having
to be moved.

Changing the reach of the machine by operating cylinder 1 and 2 together

Extra equipment
The machine can be supplemented with additional equipment. Extra equipment is fixed to the
machine, such as, an extra hydraulic function or lubrication for the hydraulic breaker. Extra equip-
ment is required if the machine is to use tools such as a side-angling device or rotator, in these
cases extra hydraulic functions are used.

Tools
The Brokk machine must be equipped with the tool appropriate for the job. The weight and per-
formance requirements of the tool are important in determining the suitability for installation on
the machine. Read sections, machine data and tools and the tool suppliers instructions for more
information. Contact the machine supplier if you have any doubts.
The tools are attached to the machine via a tool mounting. The shape of the tool mounting
varies between machine models.

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System description
All the functions of the machine are based on coope-
ration between the electric system, the control system
and the hydraulic system.

Electric system
The electric system consists of power supply via
a high current circuit, a low current and a control
system. Brokk machines with diesel engines do not
have a high current circuit.
High current circuit
The electrically driven machine is connected to the
power supply using a connector. We recommend
use of a earth fault relay. For the machine to work
the power supply must be sufficiently stable and
powerful, even at full load. For further information
see "Connection to the electrical supply".
The high current is used as a power source for both Connect the machine via the earth fault relay
electric motors and low current circuits. A phase
sequence switch in the electric cabinet or in the
connector ensures that the electric motor turns in the
correct direction.

Low current circuit

Low current is produced when high current is reduced. It is used as a power supply for the start function, control
system and functions such as work lamps and filling pumps. If the machine has a diesel engine, the generator
of the engine generates the low current.

Control system
A control unit, electronic unit and pilot valves are the main components in the control system. When a control
lever or switch is affected, the signals carrying information about the present position are transmitted to a
transmitter card in the control unit. The signal from the transmitter card to the electronic unit is transmitted via
the radio transmitter and receiver or via cable. The electronic unit transfers the signals to the relevant function
on the machine.
The signal from a control lever is proportional to the movement of the lever. A small movement of the le-
ver causes the function to move slowly. Increased movement of the lever increases the speed of the function
proportionally. The pilot valve transfers the signal to the hydraulic system by converting the electric current to
hydraulic pressure.
The signal from the switch indicates if the function is switched On or Off; the relevant function assumes
the correct position, on or off.

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Hydraulic system
The task of the hydraulic system is to provide the functions of the machine with power and motion
through hydraulic pressure and flow. The system consists of a hydraulic pump, tank, filter and dif-
ferent types of valve. Hoses or pipes connect the components to each other.
The valves are used to control the hydraulic system pressure, volume flow and direction. The
pressure controlled valves limit or reduce the pressure to a desired value. The volume controlled
valves affect the flow of hydraulic fluid and therefore the speed of the functions. The directionally
controlled valves direct the hydraulic fluid to the different functions.

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Connection to the electrical supply
One of the most common causes of malfunction in a Brokk machine is a defective connection to
the electrical supply. For safety reasons, the machine must be connected via an earth fault relay
and have a functioning protective earth. For further information see "Safety functions":

Power supply
In order for the electric motor to start and continue to run effectively, the electrical supply must be
sufficiently powerful and stable. There must be no variation caused by a voltage drop.
Insufficient voltage causes the current consumption of the electric motor, and therefore tempe-
rature, to increase until the overload relay is tripped.

Fuses
The fuses in the central electrical unit protect the electrical equipment in the event of an overload
or a fault in the connected machine. The electrical sockets used must be correctly fused. Check the
electric motor. Check the length of the power supply cable and the cross section of the conductor
in the power supply cable.
The fuse required for the electric motor can be read off from the table "Guidelines for connection
to the electrical supply" in the "Troubleshooting" section.
Slow blow fuses must be used for direct started and Y/D started machines. Circuit breakers
must be equipped for motor operation, type K or in certain cases, type D. Other types are often too
quick to blow and can therefore cause problems. Machines equipped with soft start can be started
using the more common fuse types.
If a fuse blows, first establish the cause, then replace the blown fuse with a new one of the same
voltage rating (A). Use slow blow fuses.
If the new fuse also blows, there is a fault in the electrical equipment or in the connected machine.
The cause of the fault must be established before a fuse is replaced.

Power supply cable

The machine is connected to the electrical supply using an extension cable. It is important that the
extension cable used has the correct dimensions. The cross section must be correct in relation to
the length of the conductors. If a long cable with a small cross section is used, resistance causes a
voltage drop in the cable and the overload relay or fuses will blow. Guidelines for the dimensions
of the cable can be found in the "Guidelines for connection to the electrical supply " table in the
"Troubleshooting" section.

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Safety functions
The safety functions of the machine can be divided into two groups. Safety functions for protection
of personnel and safety functions for component protection. Several of the safety functions provide
protection to both personnel and to the machine.

Protection of personnel
Zero position indication
When the control unit is started and the control circuit
is engaged the zero position indicator checks that none 0V 2,5V 5V

of the control levers are activated. Zero position is 2.5

± 0.2V. If any function passes the zero position, the
function is inhibited. The function is inhibited until
the control unit is switched off and restarted without
the control lever activated.
+- 0,2V
Zero position indication prevents the machine
from making an unexpected movement if a control Zero position 2.5V ±0,2
lever is activated when the control unit is started, in
the event of a fault in the potentiometer or if a cable
break occurred before the control unit was started.
During operation the function is only protected
against a cable break, if there is a fault in the poten-
tiometer there is a risk of incorrect activation. 0V 2,5V 5V

Signal voltage limitation

The voltage level of the control signal is limited to
within a maximum and minimum value of 0.25-4.75
V. If the voltage level is outside these values it is in-
terpreted as false activation and the machine stops. 0-0,25V 4,75-5V

Signal voltage limitation prevents the machine

Voltage limitation 0.25-4.75V
from making an unexpected movement in the event
of a cable break or a short-circuit.

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Lever gate
The lever gate opens and closes the operating voltage to the control circuit. The levers must be in
the neutral position to open the operating voltage to the control levers. If the control levers are in
the neutral position for 3 seconds the control circuit is broken automatically. If the lever gate is
open for operating voltage, the switches must be released before the lever gate can be reactivated,
therefore it is not possible to secure the switch in the active position.
The safety function prevents the machine from being activated by mistake, which might happen
if the control unit could be left with the control circuit engaged.
Radio limitation
If the control unit has been switched off for 120 seconds, the electronic unit for radio signals is
blocked. The machine cannot be started until the power supply voltage to the electronic unit in the
electric cabinet is broken and restored.
The safety function ensures that the operator knows which machine is being started, and that
the correct control unit is used, on sites with a number of Brokk machines.
Radio channels
If several radio controlled Brokk machines, construction cranes or other radio controlled machines
are close to each other there is a risk of frequency collision. Machines transmitting radio signals
on the same frequency will interfere with each other. The operator will experience frequency col-
lision as interference or interruptions in operation. The control system has 12 radio channels to
minimise the chances of frequency collision.
Identity code
Each control unit has a unique ID code which is programmed into the electronic unit. During
radio control only the machine with the same ID code programmed into the electronic unit can be
controlled by the control unit. The safety functions make it possible for several machines to work
in the same area without faulty movements in the machines.
During cable control the ID code is suppressed and the same control unit can be used for dif-
ferent machines if they have the same type of control system.
Control system stop circuit
When the mushroom switch on the control unit is pressed the power supply voltage to the con-
trol unit is mechanically broken. The machine motor stops because the transfer of signals to the
machine's electronic unit stops. The safety function switches off the energy source of the machine
and the machine freezes in position.
Protective earth
The machine and components are connected to the earth lead in the power supply cable. In the
event of a fault, the dangerous current is led off via the earth lead through the connector to the
earth protected wall socket. There is a short-circuit, the main circuit fuse breaks and the current
is broken.
The wall socket to which the Brokk machine is connected must be earth protected. If the earth
leads are missing, incorrectly connected, have disconnected or are loose in a connection the current
is not broken and touching the machine could be lethal.
If there is reason to believe that the protective earth has been damaged the machine must be
shut off and the power supply cable removed until the protective earth has been restored. The
earth lead is green and yellow striped. If the connector is pulled off, the earth lead must always be
disconnected last so the earth pin is always the longest.

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Earth fault relay
The machine must always be connected via an earth fault relay which is complementary protec-
tion to the protective earth. The earth fault relay must break at a current leakage of max 30 mA to
protect personnel.
Connect the earth fault relay as close to the electrical supply as possible. This will additionally
protect the cables to the machine.
The earth fault relay has the task of preventing personal injury or fire caused by electrical
faults.
Hydraulic brake
Hydraulic motors are used for moving the machine and the swivel mechanism on a number of
machine models. All the hydraulic drive motors and some of the swivel motors are equipped with
brakes. These hydraulic motors contain a load retaining valve which prevents an uncontrolled flow
of hydraulic fluid through the motor, for example when manoeuvring down an inclined surface
or when the machine is parked. The load retaining valve closes a port to the tank when the drive
motors are not being operated.
Mechanical brake
Brokk machines are equipped with mechanical parking brakes. The machine is braked until the
drive function is activated, when the sprung brake is released by hydraulic pressure.

Machine protection
Phase sequence relay
The phase sequence relay is an active connected electrical component. It must be active and func-
tioning for the motor to start. The phase sequence relay prevents the electric motor from starting
in the wrong direction of rotation, which could damage the machine.
Overload relay
The overload relay is an active connected electrical component. It must be functioning for the motor
to start. The overload relay prevents machines with electric motors from overloading, preventing
the consequent risks of damage to the machine and fire. Resetting is manual or automatic
Fuses
Fuses are used to protect components and to avoid fire in the event of faults or when overloading
electrical components.
Pressure limiting valve
The hydraulic systems of Brokk machines are equipped with pressure limiting valves. These
protect the hydraulic system against high pressure and mechanical components against overload.
Pump regulator
Machines with variable pumps are protected against overload by integrated pressure cut-offs in
the pump regulator.
Dump valve
The dump valve drains the hydraulic pressure to the tank when the safety stop is pressed or if the
lever gate for operating voltage to the control circuit is closed. When the dump valve drains the flow
to the tank, the pressure in the hydraulic system is released and the risk of unexpected movements
is prevented. The dump valve is not available on all Brokk machines.

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Stickers
Brokk machines are equipped with type plates, warning stickers and information stickers. Before
using the machine the operator must have read and understood the instructions regarding the plates
and stickers on the machine. Any stickers which are missing or illegible must be replaced. The
location and part number of a sticker is given in the spare part list.

Type plate
The type plate is located beside the mounting for arm one. It contains the following information:
• CE mark
• Manufacturer
• Year of manufacture
• Type designation, revision
• Serial number
• Motor data
• Machine weight

Information stickers
The sticker can indicate direction of movement, lifting points or what hydraulic fluid was in the
hydraulic system of the machine on delivery.

The sticker indicates the position of the lifting points. The number
of lifting points varies depending on the machine model.
3136 1201 44

Main circuit breaker, disconnects the battery

3136 1201 59

Tank for fuel, diesel

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Warning stickers
Warning stickers have a red border. They provide important information about risks which can
cause serious personal injury, therefore it is important that the operator has understood the meaning
of the sticker. The machine is equipped with a general warning sticker as well as specific warning
stickers which are associated to a relevant risk. The number of specific warning stickers varies
depending on the machine model.

General warning sticker

The warning symbols on the general warning sticker have the following meanings:
• 1. Danger – Read and understand the Brokk manual
• 2. Danger – Use personal protective equipment
• 3. Warning high current – Connect the machine via an earth fault relay
• 4. Warning high current – Monitor the power supply cable of the machine
• 5. Risk of splinter, falling debris - Keep your distance. Use personal protective equipment
• 6. Risk of the machine tipping/sliding - Anchor the machine. Keep your distance. Stand uphill
of the machine
• 7. Risk of crushing – locate the lifting points, attach approved lifting equipment to all the lifting
points, keep outriggers and arm system retracted, keep your distance
• 8. Risk of crushing – the risk zone varies. Keep your distance

1 4 6
2 5 7
3 8
General warning sticker

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Specific warning stickers

3136 1201 45

Warning of high current. The sticker is located on the electric cabinet of the machine.

3136 1201 58

Warning of hot surfaces, can cause serious burns if touched

3136 1200 25

Warning of entanglement, never touch rotating parts

13-TS-002340-A
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TS-000002-A.INDD
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 Handling
The most important condition for your own safety, your colleagues' safety, and the operational
safety of the machine is that the information from this manual and common sense are used.

Areas of use
The machine is intended for:
• Demolition, digging, making openings, materials handling
• Working in hazardous environments. The machine is remote controlled so that the operator can
control the machine without being within the risk zone
• Working with hydraulic and mechanical tools
• Work which requires safe positioning with good repetition
• Working indoors and outdoors. Indoor work using machines equipped with diesel engines
requires good ventilation
• Work in dangerous environments, where the machine is exposed to risk of collapse, dangerous
substances or extreme heat for example
• Work in environments classed as "fire hazards" on the condition that the connection to the
electrical network is the correct size and not damaged

The machine is NOT intended for:

• Work in areas that are classed as "explosive hazards"
• Work in water where the water level threatens damage to the electrical equipment of the
machine
• Passenger transport
• Use on the public highway
• Use as a towing vehicle or lift
• Work which endangers the lives or health of the operator or nearby personnel. Remove the risks
before starting work or use another method

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Ergonomics
Be aware that there is a risk from static loading. Vary your working position and take regular
breaks to stretch your body. Vary the work between using the control unit fastened around your
waist and using the control unit on a stand. Operate the machine using steady relaxed movements.
Using force on the levers does not increase the power of the machine, but does increase the risk
of static loading.
Adjust the control unit for the optimum working position.

Relax the shoulders by resting your hand on the control unit Vary the working position by adjusting the control unit moun-
cover ting

The control levers allow various grips. Hold the

levers in different ways to reduce the static loads.
Relax the shoulders by resting your hand on the
control unit cover. A harness to distribute the weight
of the control unit between the hips and shoulders is
available as an option.

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Regulations for environmentally
­unfriendly waste
Machine waste, such as used hydraulic fluid, filters, hoses etc., and deposited materials from
demolitions are considered environmentally unfriendly waste. Environmentally unfriendly waste
must be disposed of according to local authority regulations. Check these regulations before star-
ting work.
The following machine components must be disposed of:
• Hydraulic hoses
• Batteries
• Rubbers and plastics
• Filters
Do not release fluids such as hydraulic fluid, oil, grease and condensation from the tanks into the en-
vironment. Collect any fluids in a container and handle according to local authority regulations.

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Affecting the operational reliability of the
machine
As an operator you have a great influence on the
operational reliability and service life of the machine.
Three important factors are:
1. That the daily inspection and regular maintenance
are carried out.
2. That the working environment of the machine is
taken into account. It can affect the maintenance
of the machine and the operational conditions so
much that action must be taken.
3. That overloading is avoided by using an operatio-
nal style based on knowledge of critical situations
and machine limitations, using the methods and
tools intended for the machine and meeting our
recommendations.
This manual contains the results of many years expe-
rience of using Brokk machines compiled to provide
instructions and advice on how to use the machine.
Read, understand and follow these instructions!
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Regular service
The best method of preventing unplanned stoppages
and breakdowns and to retain the value of the machine
is by carrying out daily inspections and regular ser-
vice. Keeping the machine clean, especially before
service, reduces the risks of the hydraulic system or
the fuel system becoming contaminated. Even very
small dirt particles can cause damage resulting in
stoppages.
Extra equipment and tools must also be checked and
regularly maintained. Certain tools require repeated
lubrication during an operating shift. Read and follow
the instructions of the tool supplier.
The machine manual contains a service sche-
dule based on the operating hours of the machine.
Because the working conditions can vary, it may be
necessary to adapt the service interval to the relevant
working conditions and environment. In general the
following working conditions require shorter service
intervals:
Dusty environments
Extreme ambient heat
Work resulting in high operating temperatures
Certain components must be replaced when damaged
or worn out to preserve operational reliability. These
include components such as cylinder covers, abrasion
protection and outrigger pads. Rubber outrigger pads
have a shock absorbent effect which protects the
machine from vibrations.
The machine's working environment
The operational reliability of the machine is affected by the working environment. In harsh en-
vironments it is important to have knowledge both of what affects the machine and in what way.
The operational reliability of the machine is increased by preventative action and maintenance
appropriate to the environment.
Temperature
The ambient temperature, both hot and cold, affects the operational reliability of the machine.
Temperature variations have an effect because of the increased risk of condensation in the tanks
of the machine.
Heat
In hot environments the driver must ensure that the
machine does not overheat. Both the electrical and
hydraulic systems of the machine can be damaged
by overheating.
The temperature of hydraulic fluid is affected by
both the ambient temperature and the type of work in
progress. Continuous chipping using a hydraulic brea-
ker produces most heat. Other factors are a blocked
radiator, that the tool installed is not intended for
the machine or that the machine has internal leakage
in the pump and valves which makes it ineffective
and hot.
The highest operating temperature for hydraulic
fluid is 80°C. The temperature must not exceed 90°C
for long periods. Overheating causes deposits, sedi-
ment and fixed particles, This leads to increased wear,
damaged seals and leakage. Overheated hydraulic
fluid does not lubricate effectively which leads to
reduced performance.
Tips for avoiding overheating:
• Keep the machine, in particular the radiators,
clean.
• Ensure that the airflow is good when working
indoors.
• If there is radiant heat, the operator must note that
the localised heating could damage parts of the
machine. Screen off exposed components.
• Additional cooling is necessary when the ambient
temperature exceeds 40°C. Supply the machine
with forced cooling using compressed air. If the
site is located more than 1000 meters above sea
level the temperature limit falls to 35°C and at
2000 metres the limit falls to 30°C (5° per 1000
metres).
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Tips for avoiding damage to machinery at high mach-
ine temperatures:
• Change the hydraulic fluid and filter more fre-
quently.
• Check the seals on the machine. Seals wear out
more quickly at high temperatures. Damaged seals
can create dirt in the hydraulic system resulting
in damage to the machine.
• Rubber tracks must not be exposed to temperatu-
res exceeding 70°C. In hotter environments steel
tracks must be used.
All temperature information applies to hydraulic
fluid ISO VG 46.
Cold
Check the glycol content of the radiator if the machine
is equipped with a diesel engine. The batteries on the
machine must be kept charged. A discharged battery
can freeze and split, if possible store batteries at room
temperature.
When the hydraulic fluid temperature falls below
10°C, maximum pump pressure must not be used
until the machine has warmed up slowly, otherwise
the hydraulic system may be damaged.
The machine is warmed up as follows:
• Warming up the undercarriage. Move the outrig-
gers downwards so that the tracks are just off the
ground. Run both the drive motors, starting at a
low speed and increasing speed as the temperature
increases.
• Warming up the upper section. Swing the upper
section backwards and forwards and operate all the
cylinders in the arm system without any load.
Ensure that a temperature around 40°C is reached.
Moisture
When working in damp environments the operator
must ensure that no electrical components, for ex-
ample the connector, are in water.
The machine must not be moved in a water depth
where water might reach the electrical equipment
on the machine. The machine must not be started if
water has penetrated electrical equipment when the
machine was stationary and switched off. The motor
must be taken to pieces and oven dried. Transformers
and connectors must usually be replaced. Contact the
machine supplier or an electrical technician.
The control unit is designed to tolerate moisture
from above, such as rain. The control unit is equip-
ped with a breather filter to prevent moisture damage
caused by condensation. The switches of the control
unit and the push buttons of the levers have protec-
tive rubber hoods. If these are damaged they must
be replaced as soon as possible. The risk of damage
caused by moisture is considerable. Never use a high
pressure washer to clean the control unit or electrical
cabinet. Wipe the control unit and electrical cabinet
using a damp cloth.
Dust and dirt
If dust and dirt block the radiators of the machine,
there is a risk of overheating. If dust from rubble
penetrates the bearings of the machine it functions
as a grinding paste causing bearings and shafts to
wear much faster. This can be avoided by regular
lubrication which expels the dust. The amount of dirt
and dust can be reduced by water flushing. Clean the
machine at regular intervals.
The hydraulic system
The hydraulic system is very sensitive to contami-
nants. Particles as small as several µm (0.001 mm)
in size can get trapped in a valve and cause serious
damage and accidents. Contaminants cause wear in
components and can damage seals, valves and other
moving parts.
A correctly functioning hydraulic system is closed,
contaminants cannot penetrate the system. The risk of
contaminating the hydraulic system is greatest when
service and repair is carried out on components, re-
quiring the hydraulic system to be opened. Damaged
piston rods and seals cause the system to be exposed
to contaminants.
Keep the hydraulic fluid clean:
• Keep the machine clean, particularly before ser-
vice or repair
• Carry out the daily inspection
• Carry out regular service
• Observe cleanliness when changing tools and
carrying out service

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Transporting and lifting
Loading and unloading using a ramp
Ensure that the ramp is complete, strong enough to bear the weight of the machine, and wide
enough for the machine. Check that there is no oil or mud etc. on the ramp which could make it
slippery. Secure the ramp correctly, both at the vehicle and to the ground. The transport vehicle
must be secure so that it does not move.
The machine may start moving unexpectedly when moved on an inclined surface. Anchor the
machine. Stand uphill of the machine. Keep your distance. Position the arm system and outriggers
as low as possible to reduce the risk of the machine tipping over.

Risk of the machine tipping/sliding. Position the arm system and outriggers as low as possible. Anchor the machine.
Keep your distance

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Transportation
The machine may only be transported on a flatbed or trailer which is approved for the weight of
the machine, see the type plate on the machine. The control unit must be well protected in the
vehicle during transit.
The load position on the flat bed
The load must be placed as close to the front edge of the flat-bed as possible to prevent the load
slipping forward under braking.
Move the arm system so that it is resting against the flat-bed as low as possible. Move the
outriggers downwards without lifting the machine.
Secure the load
Secure the machine correctly using approved straps. Ensure that no machine components are crus-
hed and damaged by the straps. Check that no components are loose and liable to fall off during
transportation. If possible cover the machine.
If tools or other equipment are placed alongside the machine ensure that they are secured using
separate straps.
Regularly check that the load is secure when in transit.

Attention. Danger. Secure the load in transit

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Lifting the machine
There is a risk of injury to personnel or damage to the machine or surrounding area when lifting
the machine. Define the risk zone. Check that no one is within the risk zone when lifting.
Check that the lifting equipment and lift units used for lifting are fault free and approved for the
weight of the machine. Follow any local regulations.
The centre of gravity must be as close to the centre of the machine as possible when lifting. Fold
in the arm system before lifting.
The machine must only be lifted at those points marked with a sticker. In order to lift the machine
safely and effectively the lifting equipment must be attached to all the lifting points. The number
of lifting points varies depending on the machine model.

Risk of compression or crushing injury. Locate and attach the lifting equipment to all the lifting eyes. Keep your dis-
tance
Ensure that the weight is evenly distributed when lifting. Lift slowly and cautiously. If the machine
has a tendency to lean, use another lift or change the position of the arm system.
Ensure that no machine components are crushed and damaged by the lifting equipment. Lift
very carefully. Ensure that no part of the machine touches any nearby objects.

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Working in hazardous operating zones
Working near edges
When working on roofs, platforms, edges of shafts, holes, dykes or similar there is a risk of col-
lapse. Collapse can be caused by the footing tilting or giving way, by an incorrect manoeuvre or the
machine becoming unstable. The collapse can include rubble, tools, the machine and, in the worst
case, personnel. The risk of the machine tipping increases when the arm is extended to maximum
reach. Position the machine as close to the work object as possible.
When cable controlled machines are used where there is a risk of collapse, the control unit must
not be fastened to the operator. The control unit must be mounted on a stand.

Risk of collapse. Use a safety harness and a stand for the control unit where there is a risk of collapse.
The machine must be anchored if the ground surface is inclined or the machine is positioned less
than one metre from an edge. If several tools are used for work on an inclined surface, those tools
which are not fixed to the machine must be anchored so that they cannot fall over the edge.
The risk of tipping increases if the machine is carrying heavy tools. Anchor the machine and
work as close to the work object as possible.

Risk of crushing. The operator must stand uphill of the machine. Anchor the machine. Deploy the outriggers. Keep
your distance

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Check the following points regularly during the course of operations:
• Ensure that the machine is stable.
• Check that the machine does not slip on the surface and move towards the edge.
• Check the characteristics of the floor surface and any changes in the surface. Vibration can
reduce the load bearing capacity.
• Never stand on the control or power supply cables. Do not stand inside a loop of cable or bet-
ween a cable and the edge.

Risk of crushing or entanglement. Keep your distance

Working and movement on uneven and inclined surfaces

• Height differences, steps and inclined surfaces can create large risks when working and moving.
The narrow track gauge of the machine means that a small irregularity in the ground surface
can cause such a large degree of lean that the machine tips.
• The risk of tipping is reduced if the centre of gravity is as close to the centre of the machine as
possible. Therefore fold the arm system in as far as possible. If the outriggers, arm and tool are
placed near the ground they can be used as support when moving.
• Drive straight up or down inclines, never across. Plan the work so that the arm is uphill when
working on inclined terrain.
• Obstacles or surfaces with poor load bearing capacity can cause the machine to change direction
unexpectedly or even tip over. Always check the load bearing capacity and characteristics of the
ground before starting the machine. Watch out for holes which have been covered by materials
with low load bearing capacity.
• The caterpillar tracks give low friction against slippery surfaces. Water, dust and contaminants
can reduce the friction further. When defining the risk zone bear in mind that the reduced friction
increases the chances of the machine starting to slide.

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When working with pipes and cables
Cables and pipes may be both visible and concealed within the work object. Survey the operating
zone before starting work. Check what the risks are. Do not begin any work until you are sure that
all lines are shut off as long as work is underway or while there is a risk.
Survey the work object for cables and pipes for:
Power supply
• Electricity
• Steam
• Hydraulics
• Gas
Fluids
• Flammable fluids
• Hot fluids
• Water
Communication
• Telephone lines
• Fibre optic lines

Electrical cables
Electrical cables in or near the operating zone must be unpowered. No parts of the machine must
come anywhere near overhead power lines, the current can "jump" large distances. If the machine
accidentally comes into contact with a powered electrical cable, seal off the area or organise super-
vision to prevent anyone from going near the machine or cable. Contact the owner of the electrical
cable for further instructions.

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Operating instructions
Instructions on how to operate the machine can be found in section: "Control system"
As the operator of a Brokk machine you are handling great power. A false move or incorrect
handling can cause the machine to move, rotate or tip without warning which can cause personal
injury and material damage.
Pay attention to the machine and surrounding risk zone during operation. Always be prepared
to stop the machine in the event of a dangerous situation.
Plan the operation, otherwise there is a risk of "painting yourself into a corner". Consider where
to start and what the consequences will be, for example demolition mass, load bearing capacity
and access.

Control unit
The impact resistance of the control unit is limited. Protect the control unit during transportation
and after work is finished.
During operation the hand movements of the operator are transferred to the control system of
the machine. The signal is proportional to the movement of the lever. Forcing the control lever
violently will not cause the machine to operate more powerfully or faster, but can deform the
control lever which may require unnecessary repair as a result.
The control levers are not intended to be used for lifting the control unit. Use the yoke provi-
ded.

The yoke for lifting the control unit

Safety when operating

Training is required to use the machine's functions safely and effectively. Learn the limits of the
machine, i.e. range, capacity and stability, by learning the controls in a secluded location where
there is no danger of personal injury or material damage. Learn the following procedures.
• Learn how to stop the machine. The ability to locate the stop button quickly can be life saving
in a critical situation.
• Practice operating in different directions, at angles and on different surfaces. Also practice
precise positioning and evacuation, i.e. moving away from the work object quickly.
• Practice using the outriggers, i.e. not moving them up them more than necessary when moving.
The machine can become unstable when the outriggers are moved upwards.
• Test the stability of the machine under controlled conditions.

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Positioning in relation to the machine
A remote controlled machine does not have a designated driver's position, therefore, the basic rule
is never to stand within the risk zone of the machine during operation. Identifying the risk zone
can be difficult. The risk zone can vary depending on the object being worked on, the materials,
the working method and the tools used. Furthermore, the risk zone can vary during the course of
the work.
Think ahead! The operator must decide on a safe control position at every job. Use the safety
principle, no job is worth risking your own life, or the lives of others.
Continually define the risk zone during work. Neither the operator, nor surrounding personnel
are permitted within the risk zone during work.

Attention. Danger. Keep your distance from the machinery depending on the size of the risk zone. The size of the risk
zone varies

Position yourself outside the risk zone of the machine, preferably protected behind a wall or pillar.

When moving the machine on a flat surface always

walk behind or to the side of the machine, if there
is sufficient room. When operating or moving the
machine on an inclined surface position yourself
uphill of the machine.
Do not begin any work before you are sure of
your own safety and the safety of your surroun-
dings.

Risk of compression or crushing injury. Outriggers must be slightly

deployed when moving. Anchor the machine. Keep your distance

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Operating the undercarriage of the machine
To reduce the risk of the machine tipping over, fold the arm system in and position it in the direc-
tion of travel of the machine before moving off. The machine is turned by the left and right-hand
caterpillar tracks travelling at different speeds. To make tight turns, one track can be moved for-
wards whilst the other is reversed.
Because the front and rear of the track undercarriage look alike and the upper section swivels,
it can be difficult to distinguish the front from the rear. The sticker on the track frame indicates
forward. In the event of any doubt, carefully move the caterpillar track until direction of travel is
established.
Outriggers
It is normal for the weight of the machine to lift the outriggers off the ground when working with
hydraulic breakers or diggers . Do not allow the outriggers of the machine to lift off the ground
more than necessary for the following reasons:
• The higher the machine lifts the greater the load becomes on the other support functions. If
the load becomes too great the risk of the machine tipping or causing material damage is in-
creased.
• When working with hydraulic breakers, the breaker will eventually break through. The higher
the machine is raised when the breakthrough occurs the greater the risk that the machine will
tip over or land with great impact on the outriggers.
Simultaneously controlling the caterpillar tracks and upper section
The caterpillar tracks and upper section can be operated at the same time. See section "Control
system" The function is used to manoeuvre the machine in difficult terrain. The caterpillar tracks
are operated using the control lever pushbuttons. Operation of the arm system is unchanged.
Be alert for unexpected movement. The caterpillar tracks can be driven at different speeds cau-
sing the machine to turn when moving. The function must not be used when moving onto ramps
or during other precision manoeuvres.

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Operating the upper section of the machine
Brokk machines are tool carriers; this means that the tool does the work. Do not use
the arm system and swivel function to strike, tear or scrape. If the swivel function
of the machine fails, the upper section can become loose causing damage to the
machine and the surrounding area.
Swivel function
By swivelling the upper section of the machine, work can be carried out in several
directions without moving the machine. Note that the stability of the machine varies
depending on the direction of the arm in relation to the undercarriage. The machine
is most stable when working straight ahead or straight behind. While the machine
can work with the tool in the straight ahead position without stability problems,
the machine can tip when the arm system is moved to the side. When the upper
section of the machine is turned to the side, the outriggers must be deployed and
the arm system moved as close to the ground as possible.
It can be difficult to anticipate the direction of rotation depending on the posi-
tion of the operator in relation to the machine. In the event of any doubt, carefully
operate the swivel motion to the determined direction of travel.
Arm system
Do not use the arm if the machine outriggers are folded up. The outriggers pro-
vide stability and reduce the risk of the machine tipping.
Work as close to the work object as possible because:
• The power of the arm system and cylinders is utilized best when operating
near the machine.
• The load on components of the arm system and the turn table increases the
further the arm system is extended. Move the machine closer to the work object
instead of extending the arm system.

Move the machine closer to the work object instead of extending the arm system
The risk of tipping is increased when the arm system is extended. The reach of the
machine is an advantage in cases where the work object cannot be reached, but the
machine must always be positioned as close to the work object as possible.

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By operating cylinder 1 and cylinder 2 at the same time the reach of the machine
can be adjusted without the machine having to be moved.

Changing the reach of the machine by operating cylinder 1 and 2 together

If the machine is equipped with a telescopic arm, cylinder 1 and 2 are initially
used to extend the reach. Never use the telescopic arm to press the tool against
the work object.
Do not secure the machine to fixed items, such as adjacent walls, to increase
the force against the work object. Both the machine and tool can be overloaded.

Do not brace against walls using the outriggers. Keep a distance from the adjacent walls.
The arm system of the machine can be overloaded if incorrectly used. Avoid this
by following this advice.
Do not work with the cylinders in the inner or outer limit positions. When a
few centimetres of the cylinder maximum movement are left, the hydraulic fluid
remaining in the cylinder acts as a shock absorber. The hydraulic fluid alleviates
knocks and vibrations which can cause direct mechanical damage and material
wear.

Do not work with the cylinders in the inner or outer limit positions

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There are two operating positions that put extreme strain on each cylinder.
OPERATING POSITION 1
Condition: Cylinder 1 and 2 are moved to maximum out limit position, the breaker operates upwards.
Result: The arm system is forced downwards, the force acting on cylinder 1 will pull it apart.
Remedy: Never move cylinder 1 to the outer limit posi-
tion.

Operating position 1 subjects cylinder 1 to extreme load

OPERATING POSITION 2
Condition: Cylinder 3 moved to maximum out limit position, the breaker operates downwards.
Result: The arm system is forced upwards, the force acting on cylinder 3 will pull it apart.
Remedy: Never move cylinder 3 to the outer limit position.

Operating position 2 subjects cylinder 3 to extreme load

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Starting and stopping
Instructions on how to operate the machine can be found in section: “Control system”

Pre work inspection

• Carry out a daily inspection before starting the machine.
• If the machine has been transported to the site, check that the machine is not damaged.
• Check that no tools or other objects are lying loose on the machine.

Connect the electrically driven machine

Check that the electrical socket used is supplied with the correct voltage and fuse. Check the diam-
eter and length of the power supply cable. Check that the extension cable is of the correct length
and diameter. Guidelines for the size of fuse and dimensions of the extension cable can be obtained
from the table ”Guidelines for connection to the electrical supply” in section “Machine data”.

Start the machine

Ensure that the correct machine is started, this is extremely important when there are two or more
radio controlled machines, for example, cranes, on the same site. If these transmit radio signals
on the same frequency, they can interfere with each other. For further information see section:
“Control system”
If several Brokk machines are used on the same site, there is a risk of mixing the control units.
Make a note of the machine’s reaction at start-up, do not activate the control circuit before being
sure of which machine is being operated.
Check that the phase sequence is correct
The electric motor cannot start if the phase sequence is incorrect, the phase sequence is switched
by the main switch of the machine. For further information see section “Electric cabinet's func-
tions”.
Brokk 40 and Brokk 50 have another function. The electric motor can be started despite an
incorrect phase sequence but the hydraulic pump does not provide a flow so the hydraulic func-
tions cannot operate. Switch off the engine and check the direction of rotation of the fan. There is
a sticker on the fan housing which indicates the correct direction of rotation. The phase sequence
can be changed in the connector for the power supply cable.

Brokk 40 and Brokk 50 have a connector that can change the phase sequence.

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Post work inspection
Carry out an inspection after finishing work, if any damage is detected down time can be avoided
the following day. Check that all fluids are at the correct levels, top up if necessary.

Towing
The machine is not designed for towing, damage to the machine can occur. Only tow if the position
of the machine causes a hazard or if the position is a risk to service personnel carrying out repairs on
site. Only tow if there is no other solution, e.g. lifting Only tow the shortest possible distances.
• If possible, move the outriggers up before towing the machine, otherwise there is a risk of them
getting trapped and damaged.
• The load on the towing equipment and machine components is affected by friction against the
ground surface, reduce the friction by preparing the towing route of the machine.
• If possible, tow in the direction of the tracks.
• Connect towing equipment to a lifting point, these are marked by stickers. Use towing equip-
ment intended for the relevant load.
• Chains and straps can become loose when towing. Therefore keep away from the machine.

Risk of personal injury. Chains and straps can become loose when lifting
or transporting. Keep your distance

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Diesel
General
Before starting a Brokk machine with a diesel engine, both the supervisor and operator must have
read and understood the entire Brokk manual. The manufacturer’s instructions apply to the diesel
engine, these are in a separate section behind a dividing tab in the product folder for the Brokk
machine.

Battery
General
The machine is equipped with two 12 V batteries which are serially connected and therefore supply
24 V. Never connect a fully charged battery to a discharged battery; there is a risk of explosion.
Store batteries in a warm environment, if possible, indoors. In cold climates the battery must be
kept fully charged otherwise there is a risk that it may freeze and split.
Batteries contain environmentally harmful lead. Dispose of the old battery according to local
regulations after replacement.
Connection
The battery must be connected with the correct polarity, negative terminal to earth. Remove the
negative lead first when removing a battery. Connect the positive lead first when installing a bat-
tery.
Service and maintenance
Keep the battery clean. Check that the battery terminals are correctly tightened and clean. Apply
grease to the terminals after cleaning to ensure a good connection.
Charging the battery
Warning!

b Risk of explosion. Hydrogen gas is created when batteries are charged.

Naked flames, sparks or short-circuits near the battery can cause violent
explosions. Always break the charge voltage before the charger clamps are
removed from the battery.
Connect the battery charger clamps to the battery first, then connect the battery charger to the
electrical supply. Read, understand and follow the instructions supplied by the manufacturer of
the battery charger.

Fuel
Filling
Fill the fuel tank in a well ventilated location well away from sparks or naked flames. Check that
the correct diesel grade is used. Refer to the engine manufacturer’s instructions for the correct
diesel grade
• Switch off the engine.
• Earth the filler nozzle against the tank to prevent sparks.
• Fill with fuel but do not fill to the brim. Wipe up any spilled fuel.
• Check that the tank cap is correctly tightened after filling.

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Mechanical settings
These functions are not available on all machine models.
Controlling outrigger width
Adjust the distance between the outriggers for the bulldozer blade. Release the outrigger lock and
slide the outrigger in the required direction. Lock the outrigger in place.

The spring lock is released using a crowbar

Complete bulldozer blade

The bulldozer blade can be used without the outriggers touching the ground by changing the posi-
tion of the outriggers. Pry up the spring above the bulldozer blade and move the outrigger to the
other side. Mount the outrigger so that the outrigger pad points upwards.

Mount the outriggers so that they point upwards

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Controlling track gauge
In confined passages the track extensions on the machine can be removed which reduces the gauge
of the machine. Note that the stability of the machine is impaired.

Note the tightening torques and other installation instructions in the spare parts
list

F
A
E

The track gauge of the machine can be reduced by removing the track extensions.

Removing track extensions

• Move the outriggers downwards so that the tracks are off the ground.
• Remove the power supply cable and position it so that it cannot be reconnected by mistake.
• Remove the screws (B). Pull the track frame away.
• Remove the retainer (A) and track extension (C).
• Slide the track frame towards the intermediate flange(F).
• Slide the plate (D) on the track frame and install the screws (B).
Installing track extensions
• Move the outriggers downwards so that the tracks are off the ground.
• Remove the power supply cable and position it so that it cannot be reconnected by mistake.
• Remove the screws (B). Pull the track frame away.
• Pull the track frame away and install the track extension (C) on the guides and the retainer
(A).
• Slide the track frame towards the track extension.
• Slide the plate (D) on the track frame. Screw the screws (B) and track extension into place.

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Cleaning the machine
Safety when cleaning
When cleaning the machine there is a risk of dirt and hazardous substances entering the eyes.
There is also a risk of slipping due to degreasing agents. Hydraulic fluids, oils and water cause the
underlying surface to become slippery.

Attention. Danger. Use personal protective equipment.

Dirt and hazardous substances can be released from the machine when high pressure equipment
is used. High pressure streams of water or air can penetrate the skin and cause serious injury or
death. Never direct the flow of high pressure water or air towards the skin. Use protective equip-
ment, goggles, gloves and protective clothing.

Cleaning methods
The method must be adapted to the amount of dirt on the machine, the type of dirt and whether
covers are installed or not. A mild degreasing agent can be used but avoid contact with the skin.
Cleaning methods using high-pressure washing and compressed air must be carried out with
great care, incorrect usage can damage the machine. Below are some examples:
• High-pressure washing using the incorrect nozzle or pressure can damage electrical components,
electric cables and hydraulic hoses
• The stream of high pressure water can damage the seals, resulting in damage due to penetrat-
ing water and dirt.
• Stickers can be washed away
• The surface treatment can be damaged

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Cleaning components
There are a number of components which require special attention when cleaning
Tank
Do not direct the stream of water towards the tank cap, especially if high pressure washing.
Place a plastic bag over the air filter for the tank and seal the bag using a rubber band to prevent
water from entering the tank.

Do not direct the stream of water towards the tank cap

Radiator
Allow the radiator to cool before cleaning. Use compressed air to clean the plates. If necessary, use
a high pressure washer and degreasing agent. Incorrect use of a high pressure washer or compressed
air can deform the radiator plates and therefore reduce the cooling capacity of the radiator.
• Maximum pressure 100 Bar
• Spray directly against the radiator, parallel to the
plates
• Maintain a distance of approximately 40 cm between
the radiator and the nozzle

Maintain the recommended distance

Electrical components
Clean the electric motor, electric cabinet, connectors and other electrical components using a cloth
or compressed air. Avoid water contact with the electrical components. Wipe the control unit using
a damp cloth. Never use high pressure water. Blow clean internally using compressed air.
Diesel engines
Protect the electrical components of the engine. Refer to the
instructions of the engine supplier.

Do not use a high pressure washer when

cleaning moisture sensitive components

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Before washing
Switch off the motor. Remove the power supply cable and position it so that it cannot be recon-
nected by mistake. Disconnect the battery if the machine is equipped with a diesel engine.

Risk of electric shock. Connect the machine via an earth fault relay

After washing
• Lubricate all the lubrication points of the machine
• Blow electrical connectors dry using compressed air
• Take care when starting the machine after washing. If any component has become damaged by
moisture, the operation of the machine may be impaired.

Attention. Danger. Take care when test driving.

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 Control system
Control unit
2
The signal transfer from the control unit to the elec-
tronic unit of the machine is digital and by radio or
control cable. A radio controlled machine can be 1
controlled by cable.
The radio transmitter is located in the control unit.
The electronic unit and radio receiver are located in
the electric cabinet of the machine.
1. Control unit
2. Radio transmitter
3. Radio receiver
4. Electronic unit

3 4

Left control lever B1 Right control lever B2

Left pushbuttons B1.LL B1.LR Right pushbuttons B2.RL B2.LL

B1 B1.LL B1.LR B2 B2.RL B2.RR

S0 H1 H3

S2 S1 H2 S3 R1 S5 S4

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Battery
During remote control the battery is located in the B2.RL
battery holder on the underside of the control unit. S1
The effective operational time of the battery is 8-10 H2
hours on a single charge. During cable control the
battery charges automatically. In extreme cold the
battery capacity and charge is diminished.
When the machine is inactive for more than 5
minutes the control unit switches off automatically
to preserve the battery, the motor will also stop.
30 minutes before the battery is completely dis-
charged the control unit gives an alert by beeping
three times and the yellow H2 LED flashes. When
the battery capacity is too low the control unit cannot
be activated. Control unit

Battery charger and battery charging

The battery charger charges at two levels; first with
high current until the battery is charged, then with 5
a maintenance charge until the battery is removed
from the charger. For safety reasons the high cur-
rent shuts off after three hours, whether the battery
is charged or not.
Normal charging time, for a drained and dis-
charged battery, is approximately 3 hours. The battery 4
charger is adapted so that the battery cassettes are not
3
damaged by long term continuous charging.
The connection voltage for the transformer must
be 230 VAC in Europe and 94-240 VAC in the rest
of the world. The battery charger is supplied with a 2
1
variety of different plugs suitable for use in different
countries.
The battery charger must be installed in a vibration
free location indoors for protection from moisture
and temperature variations. Battery charger for the control unit battery
1. Connection cable
2. Mounting hole
3. Red LED, indicates power supply voltage
4. Green LED, flashes while high current is charging, then
constant.
5. Power transformer

Secure the cable as illustrated.

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Identity code
Each control unit has a unique ID code which is
programmed into the electronic unit before delivery.
During radio control only the machine with the same
ID code programmed into the electronic unit can be
controlled by the control unit. During cable control
the ID code is bypassed and the same control unit
can be used for different machines if they have the
same type of control system.
The first window on the electronic unit display
shows if the ID code is correct or not. The code for
an incorrect ID is only shown if the control cable is
connected and the control unit has been started.
1 Correct ID code
2 Incorrect ID code
Even though the ID code is a safety precaution the
operator must ensure that the correct control unit is
used for the machine, and pay particular attention to
the reaction of the machine on starting. This is es-
pecially important when there are two or more radio
controlled machines on site.
Warning!
b Risk of unexpected movement.
If several machines are program-
med with the ID code for the same
control unit all the machines will be
controlled simultaneously by the
same control unit.
Ensure that the machines that are
not to be operated are unpowe-
red.
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Programming identity code
1. Test drive the system with cable control.
2. Check the display in the electric cabinet. If a 1 is
displayed in the first box the identity code is cor-
rect, no programming is necessary. If a 2 is shown
in the first box the identity code is incorrect and
must be reprogrammed, continue with point 3.
3. Maintain cable control between the control unit
and the machine.
4. Press in safety stop S0 on the control unit and
safety stop S02 on the electric cabinet. Note that a
time limit is integrated in the control system. Point
6 must be carried out immediately after point 5.
5. Turn up safety stop S0 on the control unit and
safety stop S02 on the electric cabinet.
6. Press switch S1 upwards and hold it for approxi-
mately 15 seconds. LED H2 will light up. As
confirmation that programming is starting, the
control unit will beep shortly after and ”P” will
be displayed in the electronic unit.
7. When programming is complete start the control
unit. Check that a 1 is displayed in the first box. If
a 2 or fault code E40 is displayed - repeat points
3-7.
If that does not work contact Brokk AB.
Changing radio channels
The operator must set the required radio channel
manually after each restart. Note that, after the safety
stop is pressed, the radio will start on the default
channel each time.
To change channel press switch S1 upwards twice
in quick succession.
The radio channel can be changed at any time
during operation but the machine will stop and the
motor must be restarted again.

Approval
This equipment is approved under FCC regulations,
section 15, and I-ETS 300 220. When using radio
control the following two conditions apply:
1. The equipment must not cause interference.
2. The equipment must tolerate atmospheric inter-
ference without uncontrolled deployment occur-
ring.
A sticker with the approval number is located in the
battery holder on the control unit, under the battery.
Changes or modifications to this equipment, which
have not been approved by an authorised testing
institution, can cause the rights of the user to use the
equipment to become void.

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Control unit functions
B1 Left control lever B2 Right control lever
B1.LL B1.LR Left pushbutton B2.RL B2.LL Right pushbutton
B1 B1.LL B1.LR B2 B2.RL B2.RR

S0 H1 H3

S2 S1 H2 S3 R1 S5 S4

Switch
S0 Stop button and safety stop. S2 Starts the electric motor.
Turn the stop button clockwise Sprungto return to centre posi-
to reset it after stopping. tion.

Engagement of on/off function

2.
S1 One press: Starting the con-
trolunit.
Second press: Activates the
sound signal. S3 Resets from reduced speed to
Two quick presses: Changes the normal speed on all functions.
radio frequency. The control levers must be in
the neutral position. Sprung to
Also used when programming return to centre position.
and testing the control unit.
Sprung to return to centre posi-
tion.

Engagement of on/off function Activation causes reduced

1. speed on all functions in five
stages. Sprung to return to cen-
tre position.

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S4 Switch S4 switches between
three different settings for
hydraulic tools. The switch is
inhibited and must be lifted in
order to set other positions.
Double-action position for, for
example, hydraulic cutters.
Single-action position for hy-
draulic breakers.
Double-action position with in-
creased working pressure.
This position must only be used with Brokk hydraulic
cutters for Brokk 180 and Brokk 330.
For Brokk 40, Brokk 50 and Brokk 90 this position
does not give any increased pressure.
NB! Single action hydraulic attachments
can be damaged if the operating
pressure is fed to the return side.
With increased operating pressure
the operating pressure is 25.0 Mpa
which can damage tools not inten-
ded for use at that pressure.
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S5 Position to operate the arm sys-
tem and caterpillar tracks at the
same time.
Operating position, the control
levers affect the upper section
of the machine.
Transportation position, the
control levers affect the lower
section of the machine.
R1 Setting the flow to the hydrau-
lic attachment. Functions only
when pushbutton B1.LL on the
left-hand control lever is de-
pressed.
If the machine is equipped with
variable flow B1.LR also ap-
plies.
H1 Green LED which lights when
the stop button S0 is turned
upwards. Displays that there
is power supply to the control
unit.
H2 Yellow LED which lights when
the control unit is engaged
when S1 is pressed once.
H3 Red LED which lights when the
control circuit is connected to
the control levers.
Left control lever B1 Right control lever B2
Left pushbutton B1.LL B1.LR Right pushbutton B2.RL B2.LL

B1 7
1. Outrigger down, left-hand side/rear
3
6
2. Outrigger up, left-hand side/rear
5
1 2
3. Left-hand caterpillar track forwards
4. Left-hand caterpillar track backwards
5. Slew anti-clockwise
6. Slew clockwise
7. Arm 3 up
8. Arm 3 down
4

B2 1. Outrigger up, right-hand side/front

9 2. Outrigger down, right-hand side/front
7 3 3. Right-hand caterpillar track forwards
1
2
4. Right-hand caterpillar track backwards
5. Tilt in
6. Tilt out
7. Arm 2 down
8. Arm 2 up
6 9. Increase reach
5
4
8 10. Reduce reach
10

B1.LL, B1.LR B1.LL 1. Variable flow to hydraulic tool

Symbol for hydraulic tool 2. Caterpillar track backwards, when op-
erating the caterpillar track at the same
2 4 time as the upper section.
B1.LR 3. Maximum flow to hydraulic attachment
4 Caterpillar track forwards, when oper-
1 3 ating the caterpillar track at the same
time as the upper section.

B2.RL 1. Engagement of control circuit/changing

B2.RL , B2.RR
reach of the telescopic arm
2. Operating the caterpillar track at the
1
same time as the upper section
B2.RR 3. Changing reach
2
3

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Starting and stopping
Read the safety instructions before using the machine.

Before starting
The following points must be carried out each morning and before starting work at a new site.
• Carry out a daily inspection according to the "Service schedule"..
• Ensure that the machine has not been damaged during transportation.
• Check that all the outrigger pads are in position and secured.
• Check that the power and control cables are undamaged.
• Check that the power socket has the correct voltage and fusing.
• Connect the power cable via an earth fault relay.

Warning!

b Risk of electric shock. The machine

can conduct current if the power
cable is damaged. Always con-
nect the machine via an earth fault
relay. When working, for example,
in a steel core which is electrically
conductive the earth fault relay
must always be located outside
the steel core.
• Connect the control cable or select radio control.
• The operator must ensure that the correct control unit is used for the machine, and pay
particular attention to the reaction of the machine on starting. This is especially important
when there are two or more radio controlled machines on site.

Start, remedies on the machine

• Check that the safety stop buttons of the machine
are turned up. They are turned clockwise.
The following switches are not available on all ma-
chine models.
• Ensure that the electric cabinet switch S8
is in the remote control position.
• Turn switch Q1 to connect supply voltage and to
select the correct phase sequence in positions 1
or 2. With the correct phase sequence the electric
cabinet displays "-" in the first box. if "E30" is
displayed, turn the switch in the other direction.
NB! It can take up to 20 seconds before the elec-
tronics are updated so that the display gives the
correct phase sequence.

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Starting the control unit
• Turn the control unit safety stop up S0. The green
LED H1 lights and displays that there is supply
voltage to the control unit.
• Start the control unit by pressing switch
S1 upwards until LED H2 is lit.
The display on the electronic unit in the
electric cabinet on the machine shows "1-
-" or "2--", which indicates that the control
unit is in contact with the electronic unit.
Radio controlled machine
If "-" is still displayed in the first box see "Program-
ming the identity code".
Sound signal at start of control unit
If a control lever is affected so that a function is en-
gaged when the control unit starts, the H2 LED will
flash and a signal will sound in the control unit. The
affected function is inhibited until the control unit is
switched off and restarted without any of the control
levers activated.
Engaging the control circuit
• Check that neither you nor anyone else are inside
the risk zone of the machine.
• Engage the control circuit by pressing the
left hand button on the right hand control
lever B2.RL., orange LED H3 lights.
When the control circuit is engaged the con-
trol unit is always set in operating position,
which means that the control levers affect the
arm and rotation of the upper section. Set switch S5
to the drive position to operate the outriggers or to
move the machine.
Blocking
Fault code [-bL]. Read more in “Display codes and
indications” in the Troubleshooting.
Stop
• Move the control levers to the neutral position.
• Press safety stop S0.
• Leave the stop button pressed in until the next
time the machine is to be started.
Set the switch in the electric cabinet for selecting
phase sequence, Q1, to position 0 if the machine is
not to be used immediately.

Starting the motor

H1
Electric motor S2
S0

Start the electric motor by pressing switch

S2 upwards. Keep the switch pressed in
until the tail lamp on the machine lights.
If the machine does not have a tail lamp
hold the switch until the motor revolutions
have increased.
Diesel engines
H2 S1
• The main switch of the machine must be switched
on.
• Press switch S1 upwards and wait until the glow A
plug lamp (A) on the electric cabinet display has
gone out.
• Press switch S2 up until the engine starts.

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Operating B1 B2

Operating the undercarriage

S5
To operate Brokk machines both the control unit and the machine
must be started and the control circuit must be connected. See
"Starting and stopping".

Operating the outriggers

Set switch S5 to the driving position.

Switch S5 in the driving position

LEFT CONTROL LEVER B1 RIGHT CONTROL LEVER B2

• With folding outriggers the left-hand side is op- • With folding outriggers the right-hand side is
erated operated
• With bulldozer blades the rear blade is operated • With bulldozer blades the front blade is oper-
ated

Outriggers down Outriggers up Outriggers up Outriggers down

Operating the caterpillar tracks

The machine is turned by the left and right-hand caterpillar tracks travelling at different speeds.
To make tight turns, one track can be moved forwards whilst the other is reversed.
Set switch S5 to the driving position.

LEFT CONTROL LEVER B1 RIGHT CONTROL LEVER B2

Left track drive forward Right track drive forward

Left track drive reverse Right track drive reverse

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Operating the caterpillar tracks and arm system
With switch S5 in the position for simultaneous operation of the caterpillar tracks and arm sys-
tem the caterpillar tracks can be driven backwards and forwards at the same time that the arm is
operated. The function is used to manoeuvre the machine in difficult terrain. Use of the arm can
increase the manoeuvrability of the machine.
The function is equipped with twin command for safety. Both B1.LR and B2.RL must be held
in while moving. Operation of the arm system remains the same but parallel and tool operation
are inactive.
Caution!

a Risk of unplanned turns. The caterpillar tracks can be driven at different

speeds causing the machine to turn when moving. Because of this the
function must not be used for moving on ramps or other precision driving.
When movement requires precision, set switch S5 to the transport position
so that the machine can be steered.

B2.RL
B1.LR
B1.LL

Set switch S5 in position as illustrated S5

Moving forward

B1.LR B2.RL
Right pushbutton on the left control lever Left pushbutton on the right control lever

Moving backwards

B1.LL B2.RL
Left pushbutton on the left control lever Left pushbutton on the right control lever

Note that both B1.LL and B2.RL must be held in while moving.

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 Operating the upper section
B2
To operate Brokk machines both the control unit and the machine B1
must be started and the control circuit must be connected. See
"Starting and stopping".
S5

Set switch S5 to the operating position.

Switch S5 in the operating position

LEFT CONTROL LEVER B1 RIGHT CONTROL LEVER B2

Arm 3 up Arm 2 down

Slew anti-clockwise Slew clockwise Tilt in Tilt out

Arm 3 down Arm 2 up

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Changing reach
The reach of the machine is changed by operating B2.RL B2.RR
cylinders 1 and 2 together.
B2

S5

Switch S5 in the operating position.

• Activate the function by pressing in the right pushbutton

on the right control lever B2.RR.
• Control movement using the right control lever B2.

Increasing reach

Reducing reach

Telescopic arm
• Activate the function by pressing in the right pushbutton
on the right control lever B2.RL
• Control movement using the right control lever B2.

Increasing reach

Reducing reach

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Operating hydraulic tools
Brokk machines can be equipped with a number of different types of tool. Operation of single-ac-
tion and double-acting hydraulic tools is described in this chapter. Machines with tools equipped
with rotators or grapples which use proportional functionality are equipped with extra hydraulic
functions which are described in the chapter "Extra equipment".
Always read the separate safety precautions and handling instructions from the relevant tool
manufacturer before using a new tool.
To operate Brokk machines both the control unit and the machine must be started and the control
circuit must be connected. See "Starting and stopping".
B1.LR
B1.LL

S4
S5

R1

Operating single-action hydraulic tools

• Set switch S5 to the centre position as illustrat-
ed.

• Switch S4 set to the centre position as illustrat-

ed.
Note that switch S4 is inhibited and must be lifted
into position.

Select maximum hydraulic flow or adjustable flow

to the tool.

B1.LL B1.LR

The flow to the hydraulic tool can be varied using poten- The flow to the hydraulic tool is maximum.
tiometer R1.

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Operating double action hydraulic tools
Always reset to single action position when a double action tool is disconnected from
the machine, by setting switch S4 to the neutral position.

REDUCED PRESSURE
• Set switch S5 to the operating position.
• Set switch S4 to the position for double action tools.
Note that switch S4 is inhibited and must be lifted into
position.
• Activate the tool B-port using the left control lever
pushbutton B1.LL. The flow to the hydraulic tool can
Switch S5 Switch S4
be varied using potentiometer R1.
Note that the flow to the hydraulic tool is greatest when the
tool A-port is activated using the left control lever pushbut-
ton B1.LR.

B1.LL B1.LR

INCREASED PRESSURE

NB! • This position must only be used for tools intended for increased pressure.
• Ensure that the power output does not exceed the power rating of the machine.
• Single action hydraulic tools can be damaged if the operating pressure is fed to the return
side.
• With increased operating pressure the operating pressure is 25.0 Mpa which can damage tools
not intended for use at that pressure.

• Set switch S5 to the operating position.

• Set switch S4 to the position for double acting
tools with increased operating pressure. Note
that switch S4 is inhibited and must be lifted into
position.
• Activate the tool B-port using the left control lever Switch S5 Switch S4
pushbutton B1.LL. The flow to the hydraulic tool
can be varied using potentiometer R1.
• Activate the tool A-port using the left control lever
pushbutton B1.LR.The flow to the hydraulic tool
is maximum.

B1.LL B1.LR

TS-001784-A.indd
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Adjusting hydraulic pressure to the tool
These instructions only apply if the machine is equipped with proportional pressure control valves UP1.
In order to use different types of hydraulic tools without overloading the engine, the hydraulic pressure and flow
must be adjusted so that the power drain does not exceed the maximum output of the motor.
If the machine is powered by a diesel engine, reduced speed or stalling means that the engine has been
overloaded. In this instance, the hydraulic pressure to the tool must be adjusted.
If the machine is powered by an electric motor, any overloading is controlled by the current consumption in
the incoming phase being read under load. Load by activating the breaker at the same time as operating an arm
function to the limit position. If the current consumption exceeds the setting value for thermal overload relay
according to the table ”Guidelines for connection to the electrical supply”, the pressure must be reduced.
Warning!

b Risk of electric shock. Touching components connected to power supply

voltage can cause serious injury. Readings from the electric cabinet must
only be carried out by authorised electricians. Brokk electric cabinet. Con-
nect the machine via the earth fault relay.

Adjusting • Immediately press switch S3 upwards a few times

• Connect the control cable between the control
unit and the machine. Remove the battery for
radio control.
• Set all on/off functions of the control unit to the off
position. Set switch S4 to the centre position.
in quick succession until the horn in the control
unit sounds for a long time and the display displays
”Pr1”. If ”Pr1” is not displayed the time limit has
been exceeded.

Switch S3

Switch S4 • Wait 5 seconds for the next horn sound, then

press switch S1 upwards once. The horn sounds
• Depress the safety stop of the control unit and for a short time every five seconds and the dis-
electric cabinet. Then turn them upwards again. play displays ”PPb” to confirm that the correct
After turning the safety stops upwards there is a time programming mode has been reached. When the
limit in the control system to reach the programming horn sounds, LED H2 flashes as well.
position. If the time limit is exceeded - depress and
turn the safety stops upwards again.
• Start the control unit using switch S1. The first
display window displays ”1” or ”2”.

Switch S1

• Start the engine using switch S2.

Switch S1

Switch S2

TS-001563-A.indd
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• Keep pushbutton B1.LR, tool function, depressed.
At the same time adjust the pressure using Switch
S3. Increase pressure with the switch up. Reduce
pressure with the switch down.

Pushbutton B1.LR

Switch S3

Increase pressure Reduce pressure

NB! The set pressure must never ex-

ceed the maximum pressure spe-
cified by the tool supplier.
To ascertain the correct pressure, the current consump-
tion is read on the incoming phase when the tool is
used. The current consumption must not exceed the
set value for thermal overload relay according to the
”Guidelines for connection to the electrical supply”
table.
• When the correct pressure has been achieved, the
safety stop is depressed to lock the set value.

TS-001563-A.indd
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Electric cabinet functions
P1 Hours counter, displays the S8 Emergency operation For fur-
operational time of the machi- ther information see section:
ne. ”Troubleshooting”.

Remote control. The machine is

Q1 Main circuit breaker and phase
controlled via a control unit.
switch.

0 Power supply voltage to the machine

interrupted. S9 Hydraulic fluid temperature
1-2 Power supply voltage connected. Se- is displayed on the electronic
lect position 1 or 2 for correct phase unit display when the switch is
sequence. pressed in.

S02 Stop button and safety stop. S16 Breaker lubrication shut off.
Turn clockwise to reset after
stopping.

Breaker lubrication activated.

S20 Pressed in to activate the filler

pump for hydraulic fluid.
S22 Switch for resetting radio inhi-
bitor. Only Brokk 40 and Brokk
50.

S2 Starts the electric motor during

emergency operation

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 Tools
General
Read, understand and practice the handling instructions in the Operator's Manual for the machine
before starting work with tools. Always read the separate safety precautions and handling instruc-
tions from the relevant tool manufacturer before using a new tool.

Positioning of tools
When a tool is not being used it must be positioned so that it does not cause a hazard. Ensure that
it is stable and cannot tip. If the tool is positioned at height or on an incline it must be secured so
that it cannot be set in motion or fall. Position the hydraulic connectors for the tool so that they
cannot be damaged or deformed and are protected from dirt.

Hydraulic settings
Depending on the Brokk machine being used the control unit has a number of settings that can be
applied to different types of tool. The flow to the tool can be steplessly adjusted, in one direction,
and different pressure levels can be selected. For further information see section "Control system".
Ensure that the settings are correct for the relevant tool before using it.

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Changing tools
Brokk machines have either fixed tool mountings or mechanical quick hitches. Regardless of the type of mount-
ing the operator must always ensure that the mounting and tool are correctly installed and secured. A tool which
comes loose unexpectedly can, in the worst case, cause personal injury. Therefore, it is very important to check
the tool and mounting. Carry out a daily inspection and regular service.
Caution!

a Risk of personal injury. Changing the tool can mean that

the operator must be within the risk zone of the machine.
Pay close attention to the machine. Be prepared to shut the
machine down. Take care to keep hands and feet from being
crushed.
Ensure that no one accidentally operates the machine during a tool change. Ensure that the machine is on a
stable surface with lowered outriggers. Never change tools without first defining the risks and risk zone.

Fixed tool mounting

Brokk 40
The tool is mounted directly onto the arm using two
shafts and lock pins.
Installing
3
• Position the tool so that it is turned towards the
machine, the hydraulic pressure port of the tool 1
on the left hand side seen from the machine. 2
• Operate the arm of the machine so that the holes
in arm 3 align with the tool.
• Knock the upper shaft (1) in.
• Operate cylinder 4 so that the hole in the link aligns
with the tool and knock in the lower shaft (2).
• Lock both the shafts using lock pins (3).
Removal
Secure the tool mounting
• Operate the arm system. Position the tool on the 1 Upper shaft
ground, turned towards the machine. Position the
2 Lower shaft
arm as flat and stable as possible.
3 Lock pin
• Disconnect any hydraulic hoses. See chapter “Con-
necting tools to the hydraulic system”.
• Remove the lock pins.
• Knock the shafts out.

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Fixed tool mounting
Brokk 50
Installing
• Position the tool with the mounting turned towards
the machine. The hydraulic pressure port of the
tool on the left hand side seen from the machine.
See illustration 1.
• Manoeuvre the link into the upper hole’s guide.
Raise the tool slightly and tap in the shaft (1). See
illustration 2.
Image 1
• Lock the shaft using the lock pin (2).
• Raise the tool so that it is freely suspended in the
air. Operate the arm of the machine so that the
holes in arm 3 align with the tool.
• Tap in the other shaft (3) and lock using the lock
pin (2). See illustration 3. 2
Removal
1
• Operate the arm system and position the tool on the
ground, turned away from the machine. Position
the arm as flat and stable as possible.
• Disconnect any hydraulic hoses. See chapter “Con-
necting tools to the hydraulic system”.
• Remove the lock pins.
• Knock the shafts out. Image 2

Image 3

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Mechanical quick hitch
The tool mounting has two shafts. When the piston rod in cylinder 4 is operated inwards these
two shafts fall away from each other and lock the tool. The tool mounting is secured using a two
part wedge and a lock pin.
Caution!

a Risk of injury if the tool comes loose. If the lock pin is not installed or comes
loose, the wedges can slide out and the tool can come loose. Check that
the wedges and lock pin are securely installed.

1. Upper shaft
2. Lower shaft
3. Fixed wedge
4. Moving wedge
5. Lock pin

Mechanical quick hitch

Installing
• Position the tool so that it is turned away from the
machine, the hydraulic pressure port of the tool on
the left hand side seen from the machine.
• Move the quick hitch shafts together by moving
cylinder four out.
• Operate the arm system so that the tool hooks into The starting point for tool changes is that tools with mounting
place against the upper shaft (1). hooks must be located as illustrated.
• Lift the tool carefully so that the shaft (2) moves
into the correct position.
• Move the quick hitch shafts apart by moving • Knock the wedge (4)out.
cylinder four in. • Remove the wedge (3).
• Insert the wedge (3). • Move the quick hitch shafts together by moving
• Insert the wedge (4) so that the shafts are locked cylinder four out. The lower shaft disconnects
against the hooks on the tool without any play. from the tool. Moving the arm upwards facilitates
Ensure that the lug on the wedge (4) is turned as this.
illustrated. • Move cylinder three in so that the mounting sepa-
• Lock the wedge in the knocked in position. Insert rates from the tool.
the lock pin (5) through the one of the holes or
grooves in the wedges.
Removal
• Operate the arm system. Position the tool on the
ground, as flat and stable as possible.
• Disconnect any hydraulic hoses. See chapter “Con-
necting tools to the hydraulic system”.
• Remove the lock pin (5).

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Connecting tools to the hydraulic system
When connecting a tool to the hydraulic system ensure that:
• No dirt penetrates the hydraulic system
• Enclosed hydraulic pressure is released
• Hydraulic fluids of different types are not mixed
• The tool is installed correctly.
Cleanliness
Dirt in the hydraulic system is one of the most common causes of stoppages. The risk of contami-
nating the hydraulic system is greatest when the otherwise closed hydraulic system is opened, such
as for tool changes. Prevent dirt entering the system by:
• Wiping any dirt from the connections, both before the tool is re-
moved and before it is installed.
• Installing dust caps on the hydraulic connectors on the machine
when no tool is installed.
• Ensuring that hoses on the tool are always connected to each other
when the tool is not attached to a machine.

Connecting the hydraulic hoses to each other when the tool is

not connected to the machine

Release any trapped pressure

Quick couplings cannot be connected to each other
if pressure is trapped in the hoses.
• Relieve the arm system against the ground.
• If the machine is equipped with hand levers on the
main valve, release the pressure by moving the
levers to their limit positions. NOTE The machine
must be switched off.
• If the machine is not equipped with hand levers
on the main valve, wait until the pressure has
Attention. Danger. Trapped pressure can cause injury. Rest the
dropped via internal leakage. arm system on the ground. Wait for the pressure to fall.
When working with double-action tools, high trapped
pressures can be avoided by not moving the tool to the
limit position just before the tool is to be removed.

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Correct connection of tools
Read the tool supplier’s manual and ensure that the tool is correctly attached. Correct connection
includes both correct attachment and correct pressure use.
NB! There is a risk of damage to the machine if operating pressure is fed in on
the return side of a single-action machine, or if the settings of the control unit
are not correct for the relevant tool. For further information about the control
unit settings see “Control system”:

Connecting tools Connecting positioning tools

The tool feed connection must be connected to the A side-angling device must be connected to extra
main valve A port for tools via the feed hose located hydraulic function 1 and a rotator to extra hydraulic
on the left hand side of the machine. If the machine function 2.
is equipped with quick couplings the connection is
For further information; see the machine’s hydraulic
female.
diagram and spare part list.
The tool return connection must be connected to
the main valve B port via the return hose located on
the right hand side of the arm system. If the machine
is equipped with quick couplings the connection is
male.
Main valve A and B ports can be found in the
spare parts list.
Single-action and double-action tools are attached
in the same way with the exception of the Brokk 40
and Brokk 50. See the instructions below.

BROKK 40, BROKK 50, BROKK 160,

BROKK 400
Double-action tools must be attached to return line
B2, which leads to the main valve on the right hand
side of the arm.

Connecting the double-action tool

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Using tools
General
Before attaching a tool to a Brokk machine the operator must ensure that:
1. Use of the tool does not contravene the Brokk machine's intended use
2. Using the Brokk machine as a carrier does not run contrary to the tool manufacturer's recom-
mendations
NB! Read, understand and follow the tool manufacturer's recommendations! It is
very important that the instructions for safety, usage and maintenance are
followed. Minimise the risk of stoppages by checking the limits of the tool.
Check what materials can be handled and what sizes.

Selecting tools
Both mechanical and hydraulic tools can be used on the machine. Hydraulic tools can be single
or double action. A single-action tool applies power in one direction only, for example a hydraulic
breaker. A double-action tool applies power in two directions, for example a concrete crusher.
Check the following before attaching a tool to the machine:
• Does the machine have sufficient hydraulic functions available to operate the tool or must extra
hydraulic functions be added?
• What requirements for hydraulic pressure and hydraulic flow does the tool have? Compare the
requirements with the capacities for the Brokk machine given in the machine data.
• Does the tool have limits for pressure levels or similar. Tools with hydraulic motors may need
the pressure to be reduced depending on the type of seals.
• How much does the tool weigh?
• Excessively heavy tools expose the components of the machine to overload with the resultant
risk of breakdown. The load and stability diagrams for the machine only indicate the permitted
weights for the stability and lifting capacities of the machine. Even if the stability of the machine
is not affected by a particular tool, there is a risk of the machine being overloaded depending on
the driving style of the operator, the performance of the tool, and the relevant work. Overload
increases the wear on the arms, bearings, cylinders and slew functions. Overload can be caused
by incorrect use, careless driving or use of excessively heavy tools.
Positioning equipment
The rotator and the side-angling devices are examples of equipment which, in combination with
tools, can be used for positioning. Positioning equipment and tools must be combined in such a
way that the operational safety of all components is good. A tool combined with a side-angling
device gives a tool carrier increased loadings in other directions. The total tool weight must never
exceed the recommended value. Contact the machine supplier for advice. Note that as the reach
of the machine increases when the machine is equipped with positioning equipment, the risk of
the machine tipping also increases.
Read the supplier's instructions.

TD-007308-A.INDD
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Bucket
The bucket is intended for moving material. It is not
intended for use as a lifting tool. When excavating it
is important that straight edges are not dug because
of the risk of collapse.
The bucket, supplied by Brokk AB, has a sticker with
the CE mark, the name and address of the supplier
and the following warning information:
• Attention. Danger. Read the tool carrier manual.
• Risk of crushing. Ensure that the tool is cor-
rectly and securely attached. Read the tool carrier
manual.
• Risk of crushing. Keep your distance.

Brokk AB • Box 730 • SE-931 27 Skellefteå • Sweden

3136 1201 18

Warning and information sticker, on the Brokk bucket.

Hydraulic breaker Clamshell bucket

The hydraulic breaker is intended to demolish through
chipping. It is not intended for use as a crowbar. Read
the supplier's instructions. Continuous chipping by
the hydraulic breaker can cause high temperatures in
the hydraulic system. Read about the risks of high
operating temperatures in the section: "The machine's
working environment".
Concrete crusher
The concrete crusher uses the jaws to crush and
cut materials. It is not intended for use, with Brokk
machines, pulling and prying loose material. Read
the supplier's instructions.
Cutters
The cutter is intended to remove surface material. Do
not use the cutter tool without load from the intended
material, this can cause the tool to damage the mach-
ine. Ensure that the cutters have the correct direction
of rotation. Read the supplier's instructions.
The clamshell bucket is intended for digging and
handling material. It is not intended for use, with a
Brokk machine, as a lifting tool. Read the supplier's
instructions.
Steel shears
The steel shears are intended to cut material. Read
the supplier's instructions.
Saw
The saw unit can be equipped with either a disc saw or
a chainsaw. The saw unit is equipped for cutting and
making holes in material according to the supplier's
specification. Ensure that the guard is secured, if the
saw blade shatters, material can be thrown. Read the
supplier's instructions.
Drill
The drill is only intended for making holes. Read the
supplier's instructions.

Grapple
The grapple is intended to handle material. It is not
intended for use, with a Brokk machine, as a lifting
tool. Read the supplier's instructions.

TD-007308-A.INDD
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 Extra equipment
General
The following section describes Brokk extra equipment. This is not available for all machine models.
Some extra equipment is supplied as standard with certain models of machine. There may also be
supplementary documentation from another supplier. See section “Other manuals”.

Extra hydraulic function

Extra hydraulic functions are used if the machine is to be used for more functions than the standard
control and hydraulic system allows. When switch S1 respectively S2 is set in position for extra
function one of the machine’s standard proportional functions is replaced. The spare parts list and
hydraulic diagram show which quick couplings on the machine’s arm system cover extra hydraulic
function 1 respectively 2.

Set switch S5, to select the operating mode, in position

for operating the machine’s upper section.

Extra hydraulic function 1

• Set switch S2 for extra hydraulic function in the ON position.
Replaced function Control section Quick coupling Control lever B2
Cylinder 10.16 cm 1VY3A XAVT1.A Left B
Cylinder 4 out 1VY3B XAVT1.B Right A

Run the function as illustrated.

Left Right

Extra hydraulic function 2

• Set switch S1 for extra hydraulic function in the ON position.
Replaced function Control section Quick coupling Control lever B1
Cylinder 3 in 1VY2A XAVT2.A Rotation clockwise A
Cylinder 3 out 1VY2B XAVT2.B Rotation anti-clockwise B

Run the function as illustrated.

Clockwise

Anti-clockwise

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Breaker lubrication
The hydraulic breaker is exposed to great wear by continuous chipping. Breaker lubrication de-
creases the wear between the tip and the breaker.
NB! Check daily. Check that the reservoir contains lubricant. The tool can shatter
if there is no lubrication. Dirt is the greatest threat to the lubrication system.
Conditions must be as clean as possible when working on the system.
When a tool other than the breaker is being used the lubrication function must be switched off,
otherwise the pump will build pressure making it difficult to reconnect the lubrication line to the
breaker. If the pressure exceeds the permitted value the lubrication grease is evacuated back to the
reservoir via a pressure limiting valve. Increased pressure may be also be due to a blocked lubrica-
tion channel. Rectify the fault immediately. Insufficient lubrication can damage the breaker.
If there is an unintentional pressure build up; disconnect the lubrication line from the quick
coupling on the machine arm temporarily, the pressure will then fall.
New installation
On new installation the lubrication hose from the lubrication pump to the breaker must be filled
and bled. Connect a grease nipple and grease gun to one end. The other end should be open. Pump
the grease gun until grease comes out of the other end.

Electrically powered breaker lubrication

Electrically powered breaker lubrication is switched off at the electric cabinet as illustrated below.
It is activated using the push buttons in the left lever. B1.LL B1.LR.
Lubricating grease is filled using a grease gun or grease pump at filler nipple on the side of the
lubrication pump.
If there is grease on the machine underneath the lubrication pump it indicates that there is a stopp-
age in the line to the hammer. In event of a blockage in the line the pump continues to provide
lubrication but the grease is forced out through an over flow valve.

A filler nipple, B pressure limiting valve

NB! Deactivate the function if any tool other than a hammer is used.

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Hydraulically powered breaker lubrication
Hydraulically powered breaker lubrication is switched off using a stopcock beside the pump.
Lubrication grease is filled by replacing grease cartridges:
• Close the stopcock as illustrated (A)
• Unscrew the existing grease cartridge (B)
• Remove the sealing plug from the new grease cartridge
• Install a new grease cartridge in the housing.
The grease volume can be adjusted by screwing the choke valve under the plug (C).
• Turn clockwise = Decrease the grease volume
• Turn anti-clockwise = Increase the grease volume
Certain models of lubricating pump are equipped with function indication (D).

B
B

A
C
C

Cable drum
Brokk machines can be equipped with a cable drum for the power cable, operating cable or cable
for other equipment. The cable drum can be powered by springs or hydraulically. Take note of the
weight and location of the cable drum because the total weight and centre of gravity of the machine
are affected. If the cable drum and cable are attached to different areas of the machine the machine
must be equipped with swivel limitation to avoid breaking the cable.
If the cable is fully extended there is a risk that the connectors can be pulled apart and dam-
aged. The machine would be stationary and unpowered in the operating zone. Secure the cables
using strain relief near the connectors to avoid separated cables from being wound into the cable
drum. If a cable drum is used for the machine’s power cable the machine must be connected via
an earth fault relay.
Avoid running the machine for long periods with the power cable wound up. The wound cable will
act as a coil and cause heat which may damage the cable.
Daily check
• Check the cable drum as part of the daily check of the machine. Rectify any faults before us-
ing the machine. Check for secure installation and damage to the cable, connector and cable
ducts.
Read the supplier’s instructions.

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Swivel limitation
Swivel limitation must be used if the swivel radius of the machine constitutes a risk to personnel,
machine components of the surrounding area. Swivel limitation can be mechanical or electrical.
Caution!

a Risk of crushing injury. If any components in the function are defective or

damaged the swivel limitation function can stop working.
No one may enter the risk zone while the machine is operating.

Electrical swivel limitation has inductive sensors and flags which limit both the clockwise and
anti-clockwise rotation angles. When the upper section of the machine is operated to a certain posi-
tion a sensor detects a flag and power to the activated swivel movement is cut. When the machine
is rotated in the opposite direction the possibility of rotation in both directions is reset. Sensors
are installed in the turntable and the flags are in the slew ring gear mounting on the intermediate
section.
Daily check
Check the function as part of the daily check of the machine. Check for secure installation. Rectify
any faults before using the machine.

Forced air cooling

Equipment for extra cooling must be used in hot environments or where the work causes the com-
ponents to be exposed to dangerously high temperatures. Extra cooling is available for both the
hydraulic system and the electric cabinet. The equipment must be connected to a compressed air
system which supplies cool, oil and water free air.

Extra work lamps

Work lighting must be satisfactory and correctly located to enable the operator and nearby person-
nel to see any hazards. Good lighting is equally important for service and repair. Supplement the
machine lighting with free standing or extra fixed work lamps if necessary.

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Earth fault relay
The earth fault relay is serially connected for power supply to Brokk machines.
The earth fault relay is constructed according to EN60 439-4. It is manufactured of durable thermo-
plastic that can absorb blows even in harsh cold and has a self closing safety cover of transparent
plastic. The earth fault relay is equipped with a carrying handle and hole for hanging.
1-phase 16A and 3-phase 32 A sockets are preceded by an earth fault relay with ground current
of 30 mA.
Protection class IP 44.
Short circuit tolerance Icf= 17 kA with 16A - 32A fuse.
CE, S, FI marked.

Before work
• Always connect the machine via an earth fault relay, 30mA.
• Check that the voltage and fusing are correct before the power cable is connected to the ma-
chine.
• Check that the power cable is undamaged before connection and during work.
• Check that no one is within the risk zone.
• Check that machine set up is stable.
• Follow the instructions for the machine and tool carefully when replacing tools.

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 Fuse
1x16 A 1x16 A 3x16 A
Earth fault relay 30mA
1x16 A 1x16 A

F01 F02 F03 F04 JF01

F05

Socket for 220V 16A for hand

tools or lighting

X05 X01 X02 X06 X03 X04 X00

Input power supply 32A
Socket for power supply for Brokk
machine 16A

Socket for power supply for Brokk

machine 32A
330mm

F01 F02 F03 F04 JF01

F05

X05 X01 X02 X06 X03 X04 X00

285mm

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 Service
General
The best way to prevent unplanned stoppages and
breakdowns is to carry out daily checks and regular
services.
NB! These are general instructions,
certain check items may not be
found on your machine.
Most machine accidents occur during fault-tracing,
service and maintenance because personnel must be
within the risk zone to carry out the work. Personal in-
jury can be avoided by strict awareness of the risk.
Read and understand the safety chapter, section
"Risk factors during service and maintenance work"
and carry out "Preparations for service and mainte-
nance" before starting service work.

Service schedule
The service schedule is based upon the operation time
of the machine. Because the working conditions can
vary, it may be necessary to adapt the service interval
to the relevant working conditions and environment.
I.E. servicing must be carried out at shorter intervals
when working in hot and dirty environments.
• For further information on how to carry out checks
and service, see the instructions that follow the
service schedule.
• For information about diesel engine maintenance,
also see the engine supplier's instructions and
recommendations.
• For information about tool maintenance, see the
manufacturer's instructions and recommenda-
tions.

Checks
After carrying out checks, failures must be remedied
immediately through replacement, adjustment, repair
etc.

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Service schedule
Daily check
Daily checks must also be carried out after transportation
Symbol descriptions

1 2 3

4 5 6

Function With reference to

Wear/damage

Replacement
Level check
Lubrication

Securing

Leakage
Function
Cracks

Other

Symbol 1 2 3 4 5 6
Undercarriage and Outriggers, containing cylinders and shafts ● ● ● ●

Arm system and Tool mounting, containing cylinders and shafts ● ● ● ● ● ●

Hoses, visible hoses, for example, arm system, outriggers, tools ● ●
Power cable, connection socket ● ●
Control cable ● ●
Hydraulic fluid ●
Diesel Engine oil ●
Coolant ●
Pre-filter Draining
Diesel ●
Warning lights ●
Breaker lubrication ●
Tools ● ● ● ● ●
For maintenance of tools, extra equipment etc. also see other manuals

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Weekly service

1 2 3

4 5 6

Function With reference to

Wear/damage

Replacement
Level check
Lubrication

Securing

Leakage
Function
Cracks

Other
Symbol 1 2 3 4 5 6
Entire machine Clean the machine
Daily check Carry out
Undercarriage, Outriggers, containing cylinders and shafts ● ● ● ● ●
Drive and Track frames, including track tensioning ● ● ● ● ● Worn track
Power unit (engine, fan, fan housing, pump) ●
Radiator ● Clean
Hoses ● ●
Other hydraulic components ● ●
Slew motor, slew gear ● ●
Gear ring slew ●
Diesel Air filter, pre-filter, hoses ●
Water separator Draining
Fuel filter Draining
Fan belt ●
Water separator, forced air cooling Draining/cleaning
Breaker lubrication ●
Crusher ● ● Check jaws

Electric cabinet Cables ● Properly secured

Clean and dry Clean, dry

Components ● ● Properly secured

Rubber mountings Check that they are OK

External wiring ● ●

For maintenance of tools, extra equipment etc. also see other manuals

37-TS-002485-A
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Service / 250 hours
Function With reference to

Wear/damage

Replacement
Level check
Lubrication

Securing

Leakage
Function
Cracks
Other
Symbol 1 2 3 4 5 6
Weekly service Carry out
Hydraulic pump ● ● ● Check for noise
Drive motor, drive gear ● ●
Slew motor, slew gear ● ● ●
Gear ring slew ● ●
Hydraulic breaker ● ● Check bushing and point
Return filter and air filter for hydraulic tank ●
Servo filter ● Only applies to Brokk 90
Diesel Engine oil ●
Oil filter ●
Fuel filter ●
For maintenance of tools, extra equipment etc. also see other manuals

37-TS-002485-A
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Service / 500 hours or at least once a year
Function With reference to

Wear/damage

Replacement
Level check
Lubrication

Securing

Leakage
Function
Cracks
Other
Symbol 1 2 3 4 5 6
Service / 250 hours Carry out
Hydraulic fluid ●
Stickers ● Check that all remain in
place
Electric High current circuit ● Post-tighten bolted joints
cabinet
Pressure control filter ●
Diesel Air filter ●
Fuel filter ●

Service / 1000 hours

Function With reference to
Wear/damage

Replacement
Level check
Lubrication

Securing

Leakage
Function
Cracks

Other
Symbol 1 2 3 4 5 6
Service / 500 hours Carry out
Slew motor, slew gear ● Change oil
Slew gear, only applies to Brokk 260, 330, 400 ●
Drive motor, drive gear ● Change oil
Diesel Coolant ●
For maintenance of tools, extra equipment etc. also see other manuals

37-TS-002485-A
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Preparations for service and maintenance
The greatest risk of an accident when working with a Brokk machine is during troubleshooting, when service
and maintenance as personnel must be inside the risk zone of the machine. Personal injury can be avoided by
strict awareness of the risk. Prevent accidents by planning and preparing work.

General
• Move the machine to a safe area if it is found to
be within a dangerous area.
• Position clear markings, for example, a sign,
to inform people in the surrounding area that
service and maintenance is in progress.
• Ensure that there is satisfactory work lighting
and that it is correctly positioned. Supplement
the machine lighting with free standing work
lights if necessary.
• Be aware of the location of the fire extinguisher,
first aid kit and emergency telephone. In the
event of machine fire, initially use an ABE pow-
der fire extinguisher, alternatively a BE carbon
dioxide fire extinguisher.

Protective equipment
• Always use the necessary personal protective
equipment and do not wear loose clothing, when
carrying out service and maintenance.
• Ensure that you have access to lifting equipment,
approved to lift a minimum of 500 kg on site to
secure and lift machine components. Ensure that
safety equipment is available to mechanically
secure machine components.

TS-001615-A.indd
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Work environment during service
• The area surrounding the machine must be clean
and clear due to the risk of falling or slipping.

• Ensure that there is a sufficiently large work

area.
• Clean the machine. Dirt in the hydraulic system
quickly leads to damage and operational break
downs. See Cleaning the machine.

Raising the machine

• Raise the machine as level as possible, deploy the
arm system and outriggers. If necessary, trestle
the machine. See Trestling the machine.
• Always allow a hot machine to cool down before
starting carrying out service and maintenance.

TS-001615-A.indd
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Relieve any stored energy
• Remove any power sources so that the machine
cannot started by mistake. Electrical components
with stored energy can cause shocks.
• Switch off the motor.
• Position the phase switch S1/Q1 to position
0.
• During service work where the machine is not
required to be started, disconnect the power
cable and position it where it cannot be con-
nected by mistake. If service work requires
the motor to be running, note the risks when
working with or near to moving parts.
• Disconnect the battery if the machine is equipped
with a diesel engine.

• Release pressure from the hydraulic tank:

• Detach the air filter to release the overpres-
sure in the tank.
• Relieve the pressure in the hydraulic cylin-
ders by relieving the arm system against the
ground.
• If the machine is equipped with hand levers
on the main valve, release the pressure by
moving the levers to their limit positions.
• If the machine is not equipped with hand
levers on the main valve, wait until the pres-
sure has dropped via internal leakage.

TS-001615-A.indd
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Removal
• Always mechanically secure moving parts before
slackening off bolted joints or hydraulic hoses.
This is to prevent heavy machine parts from be-
ing set in motion or falling during removal.
• Never remove a hydraulic hose without first
checking that it is depressurised. Pipe and hose
couplings can remain pressurised despite the
motor being switched off. Always disconnect Mechanically secure any moving parts
any connections carefully.
• Ensure that all cables and hoses which are re-
moved during service and maintenance are
marked. This is necessary to ensure correct re-
connection.

Depressurise the hydraulic system.

Mark cables and hoses

Test driving the machine

• Be vigilant when test driving. If any of the con-
nectors, cables or hoses are incorrectly installed
the movements of the machine can be incor-
rect.
• If there is noise on start up read ”Fault symptoms
quick guide” in ”Troubleshooting”.

Be vigilant when test driving

TS-001615-A.indd
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Hydraulic fluid and lubricants
Hydraulic fluid
The grade of hydraulic fluid supplied with the machine is specified on the sticker positioned on
the hydraulic tank of the machine.

starting temperature
Lowest
Grade/Type Standard Operating temperature
Mineral oil ISO VG46 ISO-L-HV -17ºC +10°-+85°C (Ideally 50-75°C)
DIN 51524 / 3 HVLP
Water glycol UltraSafe 620S* ISO HFC -10ºC max +50°C
DIN 51524 / HFC
Biological oil HF-E46/ DIN 51524 / HVLD -17ºC 0°-+75°C (Ideally 40-75°C)
Shell Naturelle HF-E46 ISO 15380 HEES

Hydraulicfluids must meet the following standards: DIN 51524 HVLP, ISO 6743-4 HV and SS
15 54 34 AV.
NB! The surface treatment can be damagedif different types of hydraulic fluids
are mixed. Check the hydraulic grade of the fluid in the hydraulic system of
the machine before filling or changing the fluid.
The machine manufacturer must be consulted before any type of hydraulic fluid other than those
stated in the table above are used in the machine.
* When water glycol is used as hydraulic fluid, the service life of the cylinder seals and pump are
reduced. Extra coolant must be used.
Lubricant

Component Grade Standard

Slew transmission SAE 80W-90 API GL 5
Drive wheel transmission SAE 80W-90 API GL 5
All lubrication points with lubrication nipples NLGI 2

Tool and extra equipment

See documentation from respective tool supplier to obtain the correct quality of the lubricant so
that any guarantee from the supplier is applicable.

TS-001628-A.indd
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Checking instructions

Lubrication Outriggers and arm system

Lubricate all joints and cylinder brackets. Operate to
General
a position which allows lubrication.
The service schedule indicates where the machine The inner pipe of the telescopic arm must be
requires lubrication and how frequently. The serv- lubricated. Operate the telescopic arm to the outer
ice schedule is based on the operating hours of the limit position. Apply grease to the sliding surfaces
machine, it may be necessary to adapt the service of the arm as illustrated
interval to the relevant working conditions and en-
vironment.
Lubricate the machine more frequently if the machine
is exposed to:
• Dusty or dirty environments
• High ambient or operating temperatures
• High loads, for example, continuous chipping
using a hydraulic breaker
Caution!

a Ensure that no one starts the

machine while servicing is under-
way. When the machine has been
Lubricate all joints and cylinder brackets

moved to the desired position,

switch off the motor. Remove the
power supply cable and position
it so that it cannot be reconnected
by mistake.
1. Clean the nipple before lubrication.
2. Replace damaged or blocked nipples immedi-
ately. Lubricate the inner barrel of the telescopic cylinder

3. Use a grease gun and pump until new grease is

forced out. Use greases recommended by Brokk
in “Hydraulic fluid and lubricants”.
Tip! Make a routine of always greasing the nipples
in the same order in order to remember where all the
nipples are located more easily.

40-TS-002501-A
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Gear ring
The gear ring has separate grease nipples for bearings
and gears. To distribute the grease evenly, lubricate
then rotate and lubricate again.
1. Connect the grease gun and lubricate both the
grease nipples.
2. Retreat a safe distance, start the machine, swivel
the upper section through 90° and then shut off
the motor.
3. Repeat points 1 and 2 three times so that the swivel
bearing and swivel bearing gears are lubricated
in four locations.
NB! If the instructions are not followed
there is a great risk that the gear
ring seal will be pressed out. The
gear ring bearing will be exposed
to dirt and the seal must be re-
placed.

Slew motor - Brokk 260, Brokk 330,

Brokk 400
The slew motor bearings are lubricated at the lubrica-
tion point. The symbol to the right is replicated on
the sticker on the lubrication point.
NB! Lubricate according to the service
schedule. Excessive lubrication
can cause damage.

Fulcrum - Brokk 40, Brokk 50

• Move cylinder 1 of the arm system to the outer
limit position.
• Lubricate nipple (A).

40-TS-002501-A
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Cracks
General
A clean machine will facilitate the tracing of cracks.
The largest risk of cracks is at the joins to weld holes
and sharp edges, or where mechanical damage has
occurred to the machine. The largest risk of cracking
at a welded join is at the end of the weld.
From a safety perspective, it is important that Risk of cracking at weld joins
cracks are remedied as quickly as possible. Crucial
safety components such as the tool mounting, link,
support strut, wedge, mounting plate or cylinders must
not be repaired but must be replaced. For welding in-
structions, see section: "Welding on the machine".

Material of differing thickness increases the risk of cracking

Undercarriage
Particularly check for cracks around the outrigger
mountings both on the undercarriage and on the
outriggers, also check the slew ring mounting and the
welds between the machine body and track frame.
Arm system
Particularly check for cracks on the arm system guide,
Risk of cracking at holes
the mounting for the cylinders and weld joins.

Risk of cracking at sharp edges or small radiuses

TS-000170-A.INDD
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Securing
General
To prevent machine damage it is important that the
components are correctly and precisely secured.
Pull and feel to see if components are loose. Look
for signs of wear which could be caused by loose
components.
NB! See the spare parts list for infor-
mation about tightening torques,
grades of adhesive and other in-
stallation instructions.
Check that bolted joints are securely tightened.
NB! A bolted joint which is bonded using
adhesive must not be checked by
post tightening. If a bonded bol-
ted joint has become loose, clean
the threads before applying new
adhesive.
• Check that shafts are secure/locked. Check ex-
pander shafts by post tightening using a torque
Bolted joints
• Outrigger mounting with bolted joints to the chas-
sis.
• Track frames with bolted joints to the chassis.
• Bolted joints for the drive motor.
• Bolted joints for the slew motor.
• Upper and lower bolted joints for the slew ring
• For swivel functions with cylinders, check the
cylinder support, the gear ring against the cylinder
and the cylinder mounting.
• Bolted joints for the tool mounting
• The bolted joints for the tool to the mounting
plate.
Cables
Check that the external wiring and connectors are
correctly and properly secured.
Components in the electric cabinet
Warning!

b
wrench. Risk of electric shock.
• Check that lock pins are secure and not dam- Always ensure that the machine
aged. is not supplied with voltage before
The joints of the machine must be checked according carrying out any work on the elec-
to the service schedule. The following lists the joints trical system.
it is most important to check. • Check that components in the electric cabinet are
properly secured using your hand.
Shafts
• Check that wiring and connectors are properly
• The design of the expander shafts means that
secured.
they are never loose as long as they are regularly
post tightened. A new expander shaft must be
regularly post tightened until it is worn in. Signs
of wear on the expander shaft sleeve is a typical
indication that it has not been post tightened cor-
rectly or regularly.
NB! If an expander shaft has slid out of
position, it must be centred before
being retightened.
• If the machine shafts are locked by lock pins,
check that the lock pins are installed on both sides
of the shafts.

42-TS-002517-A
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Level check
General
The level plugs, dipsticks, sight glass or level indica-
tor lines on the holder indicate the highest and lowest
permitted levels. If any level is low, check for leakage
and remedy if necessary.
Position the machine on a flat surface. Before
opening a component for reading off or topping up,
clean to prevent dirt from entering. If the level is low,
top up with the type and grade of fluid specified in
the Hydraulic fluid and lubricants section. Level plug level indication
Caution!

a Risk of allergic reaction. Repeated

chemical contact with the skin can
cause allergies. Avoid skin contact.
Use protective equipment

Dipstick level indication

Sight glass or sight window level indication

Min 1/3

Level indicator line indication

TS-001654-A.indd
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Hydraulic fluid
• Operate the arm system inwards.
• Locate the sight glasses, they can be read without
removing the cover. If necessary, use the spare
parts list as an aid.
Slew gear
Checks only apply to machines with slew functions
equipped with a slew gear. Locate and remove the
dipstick. Wipe the dipstick, lower it and read off the
level.
Drive gear
Checks only apply to machines with drive functions
equipped with a drive gear.
• Operate the machine until one of the plugs moves A
to the same level as the centre of the hub and the
other plug is in the uppermost position.
• Unscrew the level plug (A), the oil level should
reach the top of the hole.
Breaker lubrication
The holder for lubricant is transparent. Check that Drive gear in position for level check
the holder contains lubricant.

Transparent holder allows the lubricant level to be checked.

TS-001654-A.indd
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Engine oil, diesel engine
Caution!

a Risk of burns. The machine beco-

mes hot during operation. Allow the
machine to cool before servicing

Risk of burns. Allow hot machines to cool before servicing

Check the oil level before starting or at least five
minutes after finishing work. The oil must run down
into the oil trough for a correct level reading to be
made. The oil level can be checked without having
to remove the cover.
• Remove the dipstick (1), wipe clean and rein-
sert.
• Remove the dipstick again and check the oil level. Checking the oil level
The oil level should be between the level lines
(A).

Coolant, diesel engine

The level is checked on the expansion tank of the cool-
ing system, it can be read without having to remove
the cover. Check that at least 1/3 of the expansion
tank is filled with coolant.

Min. 1/3

Checking the coolant level

TS-001654-A.indd
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Wear and damage
General
The risk of machine breakdown resulting in expensive
repair costs increases if the machine is used despite
the fact that components are damaged or worn out.
Rectify worn out components as soon as possible.
Wear shafts and plain bearings
When the play in the joints and the cylinder brackets
becomes so great that the tool becomes difficult to
control it is time to replace bearings and, if neces-
sary, shafts.
When there is play in the joints, the bearings must
always be replaced. Check that the bearing races are
not damaged. If the bearing races are damaged the
component must be replaced or repaired. All bearing
positions have H7 tolerance.
Shafts must be replaced if they have abrasion
damage.
• If an expander sleeve has abrasion damage it indi-
cates that it has not been correctly tightened.
• It is important that the line joints are well lubri-
cated to be able to push out dirt which comes in and
to minimise wear on the shafts and bearings.
Wear of rubber components
Check that the tracks and outrigger pads are in-
tact. They must be replaced if they are worn to the
metal.
Wear hydraulic hoses
Check the hydraulic hoses regularly. Check that the
hoses are not damaged. Check that the cord in the
hose is not visible. Check that none of the hoses rub
against sharp edges. Note the risk from radiated heat.
Replace any damaged hoses.

Wear electrical cables

Risk of electric shock. When the electrical cables
are checked the power supply cable must be dis-
connected. Check that the insulating sleeves of the
cables are not damaged. Replace any damaged cables
immediately.

Check that the hydraulic hoses and electrical cables do not rub
against sharp edges.

TS-000164-A.INDD
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Leakage
General
Leakage can cause serious machine breakdown. It
increases the risk of slippage at the site and is dam-
aging to the environment. The chances of detecting
leakage early can be improved by washing the ma-
chine regularly. Rectify leakage as soon as possible
and top up as necessary. Check the machine for leakage

Hydraulic fluid
Leakage of hydraulic fluid increases the risk of dirt
penetrating the hydraulic system which can lead to
malfunctions and damage to the machine.
If hydraulic fluid is detected under the machine,
on the turntable or undercarriage, there is leakage
somewhere. Check hose connections, connections
and cylinders particularly carefully. Leakage can
also occur from other hydraulic components and
can then be detected by a line of dirt. After correct
action the machine must be washed.
Engine oil
Engine oil leakage will first become apparent on the
turntable. There is a risk of engine breakdown in the
event of leakage. Do not use the engine until the leak
has been rectified. Check if the electric cabinet display
indicates that the oil pressure is low.

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Function
General
The function check ensures that the machine functions
as it should, i.e. that the direction of operation, speed
and operating characteristics are correct.
Brake functions
The function of the driving brake is checked by op-
erating the machine at an angle. Release the control
lever, the machine should brake to a stop and remain
stationary.
The slew brake function is checked by swinging
the arm on an inclined surface. Release the control
lever, the arm must then stop.
Radiator
To function satisfactorily the radiator must not be
blocked or clogged by dirt. The service life and
operational reliability of electric and hydraulic com-
ponents are diminished in the event of over heating.
If necessary, clean according to the instructions in
section “Handling”.
Cylinders
When checking cylinder barrels and piston rods, the
cylinders must be at the end limit position. Ensure that
there are no kinks or cracks in the cylinder barrels. In
the event of damage, replace immediately.
Tool mounting
The task of the tool mounting is to secure the tool
to the carrier. The tool must not, under any circum-
stances, become detached unintentionally. Worn,
defective or missing components can cause the tool
mounting to function incorrectly. Check that the tool
mounting is complete, that all parts are intact and are
correctly mounted.
SECURE THE TOOL MOUNTING
Check for cracks and secure installation.
MECHANICAL QUICK HITCH
Warning!
The wedge and pin for tool moun-
ting are important safety compo-
nents. A worn or damaged wedge
must be replaced with a Brokk
original replacement part. Do not
manufacture your own wedges.
Check the tool mounting components for cracks
and secure installation. Check that the wedge locks
the joint securely. The wedge must not be worn that
it can hit against the mounting. Check that the pin
secures the wedge so that it does not vibrate loose
during operation.

Check for damage on the cylinder barrels and piston rods

Check that the piston rods are undamaged and straight.
If the surface of the piston rod is slightly damaged
try to rub out the damage using a fine polishing cloth
before the cylinder is moved in. If damage is more
serious or the piston rod is bent - replace immediately.
A damaged piston rod can cause a contaminated hy-
draulic system resulting in damage to the machine.

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Track tension
Track tension tensions the track so that it does not
come loose during operation. Over tightening in-
creases the load and can cause break down.
• Ensure that the track is not slacker than 10-15
mm play and that it only just lies against the
carriage wheel.
If demolition material or similar enters the side of The track must not be slacker than 10-15 mm play
the track during operation, a spring function prevents
machine damage and breakdown. The spring func-
tion consists of either a hydraulic accumulator or a
spring. Lighter models of machine are not equipped
with the spring function.

AUTOMATIC HYDRAULIC TRACK TENSION- MANUAL TRACK TENSIONING

ING
Deploy the outriggers to their limit position and check
Automatic hydraulic track tensioning means that to see if the track slackens.
it is activated when the outriggers of the machine
Grease filled cylinders and springs can be adjusted
are deployed. Operate the outriggers up so that the
to achieve track tensioning by connecting a grease
pressure in the accumulator increases. Deploy the
gun to the cylinder nipple (1) and pumping to the
outriggers down to the end limit position. Wait 15
required track tension.
minutes before checking. If the track is slack this
could be due to a restrictor valve (A) or check valve
(B) of the track tensioning function being blocked
or defective.
By operating the outriggers upwards, with the
restrictor valve open, the hydraulic fluid is pumped 1
around the system and the accumulator valve is
cleaned.
• Release the pressure in the accumulator and
cylinder for track tensioning by opening the Nipple for adjusting track tension
restrictor valve anticlockwise. Operate the out- Track tensioning using the adjustment screw is carried
riggers upwards. Close the restrictor valve. Do out by slackening off the lock nut (A) and turning
not over tighten, this can damage the restrictor the adjustment screw (B) until the track is correctly
valve. Operate the outriggers up so that the tensioned. Tighten the lock nut.
pressure in the accumulator increases.

B
A
A B
B
A Restrictor valve, B Check valve Track tensioning using the adjustment screw (B) and the lock
nut (A)
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Swivel function with cylinder, adjusting
Ensure that there is no play between the gearwheel
and rack in the limit position. Swing the arm to one
limit position and rock the arm. If there is play in the
arm, slacken off the lock nut (C) and adjust using
screw (B). Then lock using the lock nut. Carry out
the same check in the other limit position.
During the entire rotational movement the cylinder
support (A) must lie against the cylinder barrel, if it
does not, adjust the cylinder support.

Brokk 40

Brokk 50: A Cylinder support, B Screw, C Lock nut

Telescopic arm
Check for play between the outer and inner barrel of
the telescopic arm. Check the cylinder and check that
the movement of the arm is smooth. Worn slide plates
cause increased play. Extremely worn slide plates can
cause damage to the outer and inner barrels due to
the screws that hold the slide plates scratching the
sliding surfaces. If the sliding surfaces of the outer
or inner barrels are damaged, they must be repaired
before new sliding plates are installed. Before replac-
ing the sliding plates, the arm system of the machine
must be secured using lifting equipment. The cylinder
bracket must be heated when being removed.
NB! See the spare parts list for infor-
mation about tightening torques, B
grades of adhesive and other in- A
D
stallation instructions.
When reinstalling the inner barrel in the outer barrel,
a press or other aid is required.
D
D
C

A Inner barrel, B Outer barrel, C Cylinder bracket, D Sliding

plates

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Air supply, diesel engine
For the engine to function correctly and not become
damaged, it must be supplied with sufficient amounts
of filtered air.
Check to see if the electric cabinet display indicates
that the air filter is sealed. Replace the filter/filter
insert if necessary.
Check that the engine does not draw unfiltered air due
to leakage, damage or defective installation.
Fuel supply, diesel engine
See manufacturer’s manual.
Fan belt, diesel engine
See manufacturer’s manual.
Coolant
Check the freezing point of the coolant using a gly-
col tester. See Technical Data for recommended
values.
Breaker lubrication
Check that lubrication reaches the breaker by remov-
ing the lubrication hose by the breaker and activating
the breaker function. If the function is driven by a
hydraulic pump, the machine must be started. Observe
great caution when carrying out checks to prevent
personal injury.
Tools
Check that the tool can be used in such a way that
neither the operator nor surrounding people are ex-
posed to danger.
Other checks - see the supplier’s manual.

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Replacement
General
Regular replacement according to the service schedule
increases service life and operational safety. Replace
fluids and filters in a manner that does not contaminate
the hydraulic system or surrounding environment.
Collect and dispose of any used material according
to local regulations.
Position the machine on a flat surface. Before
opening a component for reading off or topping up,
clean to prevent dirt from entering. Relieve the load
from the machine and allow the machine to cool be-
fore replacement. If the level is low, top up according
to the following instructions.
Caution!
TOP UP THE HYDRAULIC FLUID
Use the same type and grade of fluid as used before
draining or change according to the instructions
“Switching to another type”. The type of hydraulic
fluid used in the machine when supplied is indicated
on the sticker on the tank of the machine. A list of
hydraulic fluids recommended by Brokk AB can be
found in the “Machine data” section.
Fluid must be filled using a filling pump if the machine
is equipped with one.
Operate the machine so that the arm system cylinders
are drawn in.
• Press the stop button in the electric cabinet.
• Clean the intake hose of the filling pump. Re-
move the plug and insert the hose into the fluid

a Risk of allergic reaction. Repeated

chemical contact with the skin can
cause allergies. Avoid skin contact.
reservoir.
• Open the shut off valve.
• Start the pump by pressing button S20 and pump-
Use protective equipment.
ing to the correct level.
Hydraulic fluid • Close the shut-off valve and reinstall the plug in
the intake hose.
DRAIN THE HYDRAULIC FLUID
• Start the machine and operate the cylinders be-
Operate the machine so that the arm system cylinders
tween the outer and inner limit positions a few
are drawn in and swivel the arm system to the side.
times to expel air that may have entered the hy-
Detach the air filter to release the overpressure in the draulic system when filling.
hydraulic tank.
Place a container under the drain plug of the tank
and open the plug.
Tip: Use a cut down bottle as a funnel when drain-
ing.
• Tighten the drain plug once all the fluid has been
drained.
• Replace the return filter. Shut-off valve in the closed position

• Tighten the air filter.

If the machine is not equipped with a filling pump,
NB! Do not start the engine when the
filling must be carried out with the air filter removed.
hydraulic tank is empty. This da-
There is a large risk of dirt penetrating the hydraulic
mages the hydraulic pump.
system. Clean before removing the filter. Ensure that
the funnel or similar used is thoroughly clean.

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SWITCHING TO ANOTHER TYPE
When changing from mineral based to environmen-
tally friendly hydraulic fluid, remember that the fluids
are poor mixers. The residue of the older fluid in the
system must be less than 10 % and therefore the fluid
is changed in 3 steps.
To ensure optimum function when using environ-
mentally friendly hydraulic fluid it is important to
always use the same product, even when topping up a
small amount. Do not connect any tool with different
hydraulic fluid than that found in the machine.
Environmentally friendly hydraulic fluid has a
greater ability to “absorb” and mix water than min-
eral based hydraulic fluids. Check the water content
through regular condition analyses.
Machines that have worked many operating hours
can have deposits inside the hydraulic system. When
switching to environmentally friendly hydraulic fluid,
these deposits can be loosened. Therefore check and
replace the return filter additionally several times after
hydraulic fluid replacement.

1 2 3
A Existing hydraulic fluid, destroyed.
B Environmentally friendly oil, used as flushing oil in step 1,
destroyed.
C Environmentally friendly oil used as flushing oil. Can be
used as flushing oil 3 times.
* Flushing oil, new environmentally friendly oil or flushing oil
type C.
N New environmentally friendly oil.

STEP 1
• Run the machine to operating temperature (40-
50°C) and then operate the piston rods of the
hydraulic cylinders in. Place a container under
the drain tap of the hydraulic tank and open the
plug.
• Replace the return filter.
• Clean the hydraulic tank according to the instruc-
tions. Install the drain plug.
• Fill with flushing oil or new environmentally
friendly hydraulic fluid. Use the machine and its
functions with flushing oil for a maximum of 50
hours.
STEP 2
• Drain the fluid. Replace the return filter. Fill the hy-
draulic system with new environmentally friendly
hydraulic fluid.
• Use the machine and its functions with flushing
oil for a maximum of 100 hours.
STEP 3
• Drain the fluid. Replace the return filter. Fill the hy-
draulic system with new environmentally friendly
hydraulic fluid.

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Return oil filter
• Thoroughly clean the outside of the filter and the D A
surrounding components. Remove the air filter.
• Remove the filter cover (A). Lift the filter holder
(B) together with the filter insert (C). Remove
the over flow valve (D) or spring from the filter C B
insert.
• Remove the filter insert from the filter holder.
Remove the O-rings on both sides of the filter.
O-rings must be replaced.
Check for unusually large amounts of, and unusually
The return filter with over flow valve
large, metal particles or sealing material in the filter
holder. If this is the case, troubleshoot the hydraulic
system of the machine.
• Thoroughly clean the filter holder. Use degreasing
agent, flush using hot water and blow clean using A
compressed air. D
• Install new O-rings.
• Press the filter insert into the filter holder. Install
the over flow valve. C

• Install the filter holder in the filter housing, po-

sitioned in the tank, without damaging the O-
rings.
• Screw the cover into place and tighten so that it
is sealed. B
• Install the air filter.

Return filter with spring

Air filter
Locate the air filter using the spare parts list. Clean
around the filter before unscrewing and replacing
with a new filter.

Air filter for hydraulic tank

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Servo filter
See “Checking the filter for servo pressure” in Trou-
bleshooting.

Pressure control filter

Remove the filter. Drain the fluid from the filter holder
and clean if necessary. Replace the filter insert.

Pressure control filter

Slew gear – replacing oil.

When replacing the oil in the slew gear Brokk 330
the bearing must also be lubricated.
• Relieve the load from the machine
• Place a container under the drain plug.
• Remove the slew gear drain plug and dipstick.
• Screw the drain plug back in once all the oil has
been drained.
• Top up the oil. After 10 minutes check that the cor-
rect level has been achieved using the dipstick.

Use a cut down bottle as a funnel when draining.

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Drive gear
• Operate the machine until one of the plugs moves
to the same level as the centre of the hub and the
other plug is in the lowermost position.
• Place a container under the hub and unscrew the
drain plugs. Drain and then screw the drain plugs
back into place.
Tip: Use a cut down bottle as a funnel when drain-
ing. Level display with the level plug, draining position
• Operate the machine until one of the plugs moves
to the same level as the centre of the hub and the
other plug is in the uppermost position.
• Remove both plugs. Fill with oil in the upper hole
until oil runs out through the lower hole. Wait
approximately 10 minutes and refill. Repeat until
the correct oil level is achieved.
• Screw the plugs back into place.

Level display with the level plug, filling position

Engine oil, diesel engine

• Operate the arm system and the turntable to the
side. Take out a 20 litre container.
• Remove the cover and insert the oil draining hose
into the drain container. Unscrew the oil filler cap.
Open the drain plug of the hose and drain the oil
into the container.
• Place a container under the filter before unscrew-
ing. Hand tighten a new original filter in place.
• Reinstall the drain plug and position the hose in
the relevant place. Place a clean funnel in the fil-
ing hole and fill with oil. Volume and grade, see Drain oil using the drain hose
Technical Data.

Replace the oil filter

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Air filter, diesel engine
If the electric cabinet display indicates that the air
filter is blocked, the filter insert must be replaced and
the filter element cleaned or replaced. The secondary
element must be replaced at every fifth service for
the filter element or every two years
• Remove the filter element by slackening the wires
and pulling out the holder.
• Turn and pull the filter element from the holder.
If necessary, the filter element can be cleaned using
compressed air up to five times. It must be replaced
after a maximum of two years. Using a pen, make a
mark every time the filter element is cleaned.

Use a pipe, secured to the compressed air gun, to 1 - 2 Slacken off the wires, 3 Pull out the holder
blow clean the filter element. The pipe must be bent
to angle of 90° at one end and must be long enough
to reach the bottom of the filter element.
• Blow clean using dry compressed air, max. 5 bar,
by pulling the pipe up and down inside the filter
element until no more dust comes out.
NB! First ensure that the paper element and rubber
seals are not damaged.
Cracks and holes in the paper element can be detected
using fluorescent light from a fluorescent lamp.
NB! Risk of engine failure. Never use
a damaged filter element. Always Turn and pull out the filter element
replace with a new one.

Blow clean using compressed air, max 5 bar

TS-001693-A.indd
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The seal of the secondary element must only be broken
when replacing, it must not be reused.
• Us a screwdriver to penetrate the secondary ele-
ment seal, from the inside out. Pull both loops
upwards.
• Use both loops to obtain a hold on the secondary
element and then pull out using a slight twisting
motion.
• Push in a new secondary element.
• Press the open side of the filter element into the
holder.
• Install the holder securely. Make a note of the Break the secondary element seal
position of the dust emptying valve. It must be
pointing downwards ± 15° to the right or left of
vertical.
• Place the wires in the groove and tighten.

Pull out the secondary element by the loops

Valve for dust emptying must be pointing downwards

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Fuel filter, diesel engine
NB! Dust and dirt in the fuel filter holder can cause
malfunctions in the fuel pump and the injector nozzle.
Replace the filter and clean the fuel filter holder.
Bleed the fuel system after replacement.
Bleed the fuel system, diesel
Bleeding the fuel system can be required if any of
its components have been removed or before the
engine is used after being out of commission for a
long time.
• Fill the fuel tank as full as possible.
• Slacken off the fuel filter bleed valve (A) a few
turns. Pump fuel using pump (B) until fuel comes Fuel filter with bleed valve
out of the bleed valve. Tighten the valve again
when no more bubbles are seen.
• Check that the fuel system does not leak. If the
engine runs unevenly after bleeding, see the manu-
facturer’s manual.

Coolant, diesel engine

Caution!

a The engine must be cold when the

radiator cap is opened. When the
engine is hot the cooling system
is pressurized causing hot steam
to spray out when the radiator cap
is opened. Steam causes serious
Hot steam can spray out when the radiator cap is opened
burns. The coolant contains glycol
and is poisonous.
• Remove the right-hand rear end of the machine.
Use lifting equipment.
• Place a container under the radiator drain plug.
Open the radiator cap, the radiator drain plug
and the drain plug on the right-hand side of the
engine.
• Tighten the drain plug.
• Fill with water and glycol via the expansion
A
tank.
Drain plugs for the coolant

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Other
Drain valve for air filter, diesel
Under normal conditions the drain valve must be
opened once a week to remove large dirt and dust
particles. In dusty environments this should be car-
ried out daily.
Remove the rubber holder and empty it or hold a
hand under it and squeeze it so that it empties.

Open the drain valve (A) to remove dirt and dust

Water separator
The water separator must be drained to prevent water
and dirt entering the fuel system.
• Switch off the engine
• Slacken off the drain screw (A) so that water starts
to run out. Wait until diesel starts to run out instead
of water before tightening the drain screw.

Drain the water separator using the drain screw (A)

Cleaning the fuel tank Electric cabinet

Water and sediment collect at the bottom of the fuel Warning!
tank. Drain the tank when the tank is nearly empty
and when the machine has been stationary on an
incline for a period so that the water and sediment
has gathered near the drain plug.
b Risk of electric shock.
Always ensure that the machine
is not supplied with voltage before
carrying out any work on the elec-
Take care that not all the fuel runs out when drain-
trical system.
ing. The fuel tank is drained through the drain plug
in the bottom of the fuel tank. Slacken off the plug. • Clean and vacuum up any dirt
Drain the water and sediment until only diesel fuel • Check gaskets
runs out from the plug. Screw the plug into place • Check that components are properly secured
again. Collect any fluids in a container and dispose
according to local authority regulations. • Check rubber mountings, replace if necessary
• Check that wiring and connectors are properly
secured.

48-TS-002533-A
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Welding work on the machine
Only qualified welders may carry out welding work on the machine.

Risk of fire. The machine contains flammable fluids
and components. Do not weld immediately adjacent
to flammable liquids such as tanks, fuel lines or hy-
draulic pipes. Ensure that there is a fire extinguisher
on site, do not work alone, check after working that
sparks or heat will not start a fire.
Risk of inhalation of hazardous substances. Poisonous
gases can build up. Use extraction fans to remove
welding fumes when welding indoors. Never weld
near rubber or plastic materials. Use a breathing
mask.

Risk of inhalation of hazardous substances. Use extraction fans

and a breathing mask.
Risk of fire. Ensure that there are fire extinguishers, first aid kits
and emergency telephones on site.

Before welding
• The surface to be welded must be bare metal. Clean off any dirt or surface treatment. Use a grinder, wire
brush or sand blasting.
• Grind down any defective welds before a new welded joint is made.
• Attach the earth clamp to the object to be welded or as near as possible. If the earthing is carried out incor-
rectly, bearings, valves and electrical components can be damaged by high current.
• Disconnect the battery negative terminal and all the electrical connections to the generator when electrical
welding on diesel powered machines.
• Disconnect the electronic unit by disconnecting all cables from it.
• Remove the battery on diesel machines. Place the battery at a safe distance from the machine.
• If welding work must be carried out near the diesel tank, minimise the amount of diesel fumes by ensuring
that the tank is full.

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125
Recommended welding wire
Use welding wire suitable for the material. Welding electrodes must be dry according to the manu-
facturer's instructions.
Type Recommended material
Pipe Filarc PZ6105R
Class: AWS A5. 18-93 E70 C-6M H4
Solid OK Au wire 12.50
Class: AWS A5. 18-93 ER705-6
Pin OK 48.30
Class: AWS A5.1 E7018

Advice when welding

• When welding cracks, drill a hole in the end of the crack before starting to weld.
• Never start or finish a weld in a corner.
• If the combined plate thickness exceeds 30 mm, preheat the material to 150˚C.

Components which should not be welded

The following components should not be repaired, but should be replaced:
• tool mounting
• link
• support strut
• wedge
• mounting plate
• cylinders
• hydraulic tank
• diesel tank
• cast components

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