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Workshop manual

BREAKER
TABLE OF CONTENTS

FOREWORD WS 88

ESSENTIAL EQUIPMENT WS 89

ENVIRONEMENT WS 90

SEALS PACKAGE WS 91

DISMANTLING WS 92 ' WS 118

INSPECTION WS 119 ' WS 123

ASSEMBLING WS 124 ' WS 161

--- Stroke adjustment WS 162

INFLATING PROCEDURE WS 249 ' WS 267

TOOLING WS 268 -- WS 269

SUPPORTS WS 270 --- WS 271

WS 87 2010
FOREWORD
The contents of this manual are considered
to be proprietary and confidential for the
manufacturer and should not be reproduced
without the prior written permission of the
manufacturer.

Nothing contained in this document is


intended to extend any promise, warranty or
representation, expressed or implied
regarding the manufacturer products
described here in.
Any such warranties or other terms and
conditions of sale of products shall be in
accordance with the standard terms and
conditions of sale of such products, which
are available upon request.

The design specification of this machine has


been certified as complying with E.U.
directives. Any modification to any part is
absolutely prohibited and will result in the
CE certification and marking being rendered
invalid.

The manufacturer reserves the right to make


changes and improvements to products
without notice and without incurring any
obligation to make such changes or add
such improvements to products sold
previously.

WS 88
ESSENTIAL EQUIPMENT

Travelling crane
(mini 3,5 tons) Crane jib

Hydraulic press
(50 tons) Nitrogen bottle

Blackboard
Washbasin
Bench
(hard rubber)

Force : 3,5 tons

Support

WS 89
Operators and service personnel must
wear appropriate safety equipment,
including hearing protection, respirator,
hardhat, safety shoes, eye protection,
heavy gloves etc......

OK
Always use clean tools for
maintenance work or inspection.

OK

OK
All damaged parts , seals spoiled
or used must be thrown in the
dustbin.

WS 90
86694171

86714748
86706405 86694163

86706371 86694155
86706389

86706397

86240389

86718103

86724754

86709383

86709383
86703758

86703758

WS 91 DOOSAN
DXB190 06 / 2011
DISMANTLING

The breaker must be imperatively


deflated before any dismantling.

IMPORTANT !

Take the
nitrogen out.

DOOSAN WS 92
06 / 2011 DXB190
DISMANTLING

Center of gravity

860

1655 daN
1 Sling and lift the breaker.

WS 93 DOOSAN
DXB190 06 / 2011
DISMANTLING

2 Place the 2 wooden blocks.

200 840

DOOSAN WS 94
06 / 2011 DXB190
DISMANTLING

3 Place the breaker on the blocks.

4 Drive the pins out.

5 Take the retaining lock out.

WS 95 DOOSAN
DXB190 06 / 2011
DISMANTLING

6 With sledge hammer and slogging


ring wrench, unscrew the 8 nuts.

7 Sling the left plate.

8 Remove the nuts.

DOOSAN WS 96
06 / 2011 DXB190
DISMANTLING

9 Disengage the plate.

10 Remove the left plate.


321 daN

11 Remove the rear flange and the retaining lock.

WS 97 DOOSAN
DXB190 06 / 2011
DISMANTLING

12 Sling the right plate.


326 daN

13 Remove the tie rods and the nuts.

14 Remove the right plate and the rear flange.

DOOSAN WS 98
06 / 2011 DXB190
DISMANTLING

M20

15 Screw the lifting eyebolts.

16 Sling the breaker.

946 daN

17 Lift the breaker.

WS 99 DOOSAN
DXB190 06 / 2011
DISMANTLING

18 Remove the two retainer pins and replace


the breaker on the blocks.

6,9 daN

19 Remove the lifting eyebolts and sling the tool.

20 Remove the tool.

150 daN

DOOSAN WS 100
06 / 2011 DXB190
DISMANTLING

M20

21 Screw the lifting eyebolts.

796 daN

22 Place the breaker on the support.

WS 101 DOOSAN
DXB190 06 / 2011
DISMANTLING

23 Remove the lifting eyebolts.

4 Mark each nut, and their mounting position in the back


4 24
head.
3 1 --- Nut 1, Hole 1.........
3 1
2
2

25 Unscrew the 4 nuts.

Never use a slogging ring wrench for nuts loosening.

DOOSAN WS 102
06 / 2011 DXB190
DISMANTLING

26 Remove the nuts and the washers.

M20

27 Put back the two lifting eyebolts.

97 daN

28 Lift and remove the back head.

WS 103 DOOSAN
DXB190 06 / 2011
DISMANTLING

29 Remove the O’ring.

30 Put the lifting hook on the strike piston.

DOOSAN WS 104
06 / 2011 DXB190
DISMANTLING

101 daN

31 Lift the strike piston and the seals casing.

32 Remove the piston and dismount the seals casing.

WS 105 DOOSAN
DXB190 06 / 2011
DISMANTLING

33 Extract all seals and throw them.

34 Remove the pin.

DOOSAN WS 106
06 / 2011 DXB190
DISMANTLING

3 4 1
2
1
3
2
35 Mark each side rod, nut, and their mounting position in the
front guide and the cylinder.
--- Rod 1, Nut 1, Hole 1.........

3 1
3 1
2
2

WS 107 DOOSAN
DXB190 06 / 2011
DISMANTLING

Do not use a hammering wrench.

36 Loosen and remove the 4 tie rods.

2
3
9 daN
1

In case of seizing

WS 109

DOOSAN WS 108
06 / 2011 DXB190
DISMANTLING

How to dismantle a seized tie rod :

35

37 By drilling.

60
Ø 12

38 By cutting.

Ø 230

22

WS 109 DOOSAN
DXB190 06 / 2011
DISMANTLING

39 Remove the o’ring.

H M6

40 Screw two M6, hexa. screws, to


dismount the distribution cover.

41 Remove the outer o’ring.

42 Remove the distributor.

43 Remove the distribution box.

DOOSAN WS 110
06 / 2011 DXB190
DISMANTLING
M20

44 Screw the two lifting eyebolts.

245 daN

45 Lift and remove the cylinder.

WS 111 DOOSAN
DXB190 06 / 2011
DISMANTLING

11 46 Remove the oiler and the two lifting


eyebolts.

27

47 Remove the oiler adaptor and the threaded plug.


32

48 Remove scraper and lip seals.

DOOSAN WS 112
06 / 2011 DXB190
DISMANTLING

49 Remove the pin.

50 Remove the 4 nuts.

51 Mark the up side nut.

WS 113 DOOSAN
DXB190 06 / 2011
DISMANTLING
M20

52 Screw two lifting eyebolts.

53 Lift and remove the front guide.

253 daN

DOOSAN WS 114
06 / 2011 DXB190
DISMANTLING

54 Pull out the pins.

55 Remove the 6 o’rings.

WS 115 DOOSAN
DXB190 06 / 2011
DISMANTLING

Without extracting tool


56 How to dismantle the lower bushing.

T1 Page : WS 269

T2 Page : WS 269

DOOSAN WS 116
06 / 2011 DXB190
DISMANTLING

With extracting tool


57 How to dismantle the lower bushing.

23 daN

Page : WS 268

38

WS 117 DOOSAN
DXB190 06 / 2011
DISMANTLING

PRESS 58 How to dismantle the upper bushing.

T3 Page : WS 269

Page : WS 268

OR

DOOSAN WS 118
06 / 2011 DXB190
INSPECTION

Strike piston

WS 119 DOOSAN
DXB190 06 / 2011
INSPECTION

OK

351,5
New

DOOSAN WS 120
06 / 2011 DXB190
INSPECTION

Distributor

Distribution box

Lower bushing

OK
Ø 143
OK

Ø 148

OUT OF USE

WS 121 DOOSAN
DXB190 06 / 2011
INSPECTION

Upper bushing

205,48
New

202,5

New tool

DOOSAN WS 122
06 / 2011 DXB190
INSPECTION
Retaining pin

OK

41
45 43

180°

New
= =

WS 123 DOOSAN
DXB190 06 / 2011
ASSEMBLING

All parts must be clean and oiled with hydraulic oil


at the moment they will be mounted.

All seals and joints must be replaced by new ones.

All tooling and accessories must be clean.

All threaded screws must be greased.

DOOSAN WS 124
06 / 2011 DXB190
ASSEMBLING

1 Mount the upper and lower bushings into


the front guide.

Down

Mind the orientation.

Up

45°

FRONT GUIDE

BUSHING HOLES

WS 125 DOOSAN
DXB190 06 / 2011
ASSEMBLING

2 Mount the pins.

3 Mount 6 new o’rings.

M20

4 Screw the 2 lifting eyebolts.

DOOSAN WS 126
06 / 2011 DXB190
ASSEMBLING

5 Place the front guide on the support.

253 daN

6 Remove the two lifting eyebolts.

WS 127 DOOSAN
DXB190 06 / 2011
ASSEMBLING

7 Grease nut threads with “MOLYKOTE” grease.


EM 10

8 Mount each nut, and their original position.


4

3
3 1
1
2

OK

9 Mount the pin.

DOOSAN WS 128
06 / 2011 DXB190
ASSEMBLING

27 Mount the oiler adaptor and the


10
threaded plug.
32

300 Nm

11 Tighten the oiler.


11
Do not forget the plug.

WS 129 DOOSAN
DXB190 06 / 2011
ASSEMBLING

Deform the seals with handle before


12 mounting, as shown.

13 The lip seal in the second groove.

14 The scraper seal in the first groove.

Oil

15 Do not use grease.

DOOSAN WS 130
06 / 2011 DXB190
ASSEMBLING

16 Mount the lifting eyebolts to lift the cylinder.

245 daN

17 Mount the cylinder on the front guide.

WS 131 DOOSAN
DXB190 06 / 2011
ASSEMBLING

18 Oil and mount the distribution box.

Oil

19 Oil and mount the distributor.

Check the distributor mooves freely.

20 Mount the o’rings on the cover.

21 Mount the cover.

DOOSAN WS 132
06 / 2011 DXB190
ASSEMBLING

22 Clean the hole piston and the lifting hook.

AIR

23 Oil generously the piston.


97,2 daN

Oil

24 Put down the piston into the cylinder.

WS 133 DOOSAN
DXB190 06 / 2011
ASSEMBLING

25 Remove the lifting hook.

26 Hit the strike piston in the cylinder.

DOOSAN WS 134
06 / 2011 DXB190
ASSEMBLING

27 In a first time, mount the o’rings.

28 In a second time, mount the seals.

Mind the orientation and the color.

WS 135 DOOSAN
DXB190 06 / 2011
ASSEMBLING

29 Mount the seals.

Mind the orientation.

UP

Grease

DOWN

DOOSAN WS 136
06 / 2011 DXB190
ASSEMBLING
UP

30 Mount the seals casing.

31 Drive slowly the seals casing in the cylinder.

32 Do not exceed the “seal” limit.

WS 137 DOOSAN
DXB190 06 / 2011
ASSEMBLING

33 Mount the pin.

34 Mount the o’ring and oil the inside of the


back head.

M20

Oil

35 Mount the lifting eyebolts.

DOOSAN WS 138
06 / 2011 DXB190
ASSEMBLING

97 daN

36 Oil.

Oil

OK
Oil Oil

37 Put the back head in position above the cylinder.

WS 139 DOOSAN
DXB190 06 / 2011
ASSEMBLING

38 Mount each tie rod in its original position and


in line with the nut with same number.

2
3
9 daN
1

Avoid any shock against nuts.

3 1
2

3
1
2

DOOSAN WS 140
06 / 2011 DXB190
ASSEMBLING
Do not use a hammering wrench.

39 Tighten with handle the 4 tie rods to the bottom.

WS 141 DOOSAN
DXB190 06 / 2011
ASSEMBLING

40 Remove the lifting eyebolts.

41 Grease tie rod threads with “Molykote” grease.

EM10

Grease

4 42 Mount the 4 washers.

3 1
2
43 Mount each nut in its original position and in
correspondance with number on the back head.

3 1
2

DOOSAN WS 142
06 / 2011 DXB190
ASSEMBLING

44 Tighten in a criss---cross pattern the 4 nuts,


to put in contact back head and cylinder.

1
2

Contact!

45 Loosen the 4 nuts.

Get free!

WS 143 DOOSAN
DXB190 06 / 2011
ASSEMBLING

46 Check the back head/cylinder faces alignement.

No

No

OK
DOOSAN WS 144
06 / 2011 DXB190
ASSEMBLING

47 Check the cylinder/front guide faces alignement.

No

No

OK
WS 145 DOOSAN
DXB190 06 / 2011
ASSEMBLING

3 1 400 Nm
2

Using a torque wrench, tighten in a criss---cross


48 pattern the 4 nuts to 400 Nm.

49 Loosen the 4 nuts.

DOOSAN WS 146
06 / 2011 DXB190
ASSEMBLING
4
35
3 1

2 50 Tighten the 4 tie rods.

51 Then loosen the tie rod to 1 revolution.

Anticlockwise
360°

52 Check that the tie rod do not touch the front guide.

Clearence

200 Nm

53 Using a torque wrench, tighten in a criss---cross


pattern the 4 nuts to 200 Nm.

WS 147 DOOSAN
DXB190 06 / 2011
ASSEMBLING

Angulary tightening procedure

Mark
Make a mark on one of faces of each nut, on the
54 back head and on the tool socket.

DOOSAN WS 148
06 / 2011 DXB190
ASSEMBLING

3 1

Tighten in 2 steps
1---Pre---constraint
55 Tighten in a criss---cross pattern the 4 nuts for 1 flat.

Before

After

WS 149 DOOSAN
DXB190 06 / 2011
ASSEMBLING
4
2---Finition
3 1
56 Tighten in a criss---cross pattern the 4 nuts for
2 2 flats + 5 mm.

2 fats

+ 5mm

57 Loosen in a criss---cross pattern each nut to 5 mm.

--- 5 mm

DOOSAN WS 150
06 / 2011 DXB190
ASSEMBLING

58 Mount the lifting eyebolts.

59 Remove the breaker from its support.


796 daN

WS 151 DOOSAN
DXB190 06 / 2011
ASSEMBLING

60 Mount the lifting eyebolts.

796 daN

61 Position the breaker on the blocks.

840

DOOSAN WS 152
06 / 2011 DXB190
ASSEMBLING

62 Remove the lifting eyebolts.

63 Mount the rear flange.

326 daN

64 With a sling mount the right plate.

WS 153 DOOSAN
DXB190 06 / 2011
ASSEMBLING

66 Mount the 8 tie rods.

67 Mount the rear flange.

321 daN

65 Mount the left plate.

DOOSAN WS 154
06 / 2011 DXB190
ASSEMBLING

69 Grease threaded tie rods.

EM10

Grease

68 With handle mount the 8 nuts.

WS 155 DOOSAN
DXB190 06 / 2011
ASSEMBLING

70 Sling and mount the support.

38

71 With a torque wrench, tighten in a criss---cross


pattern the 12 nuts to 350 Nm.

350 Nm

DOOSAN WS 156
06 / 2011 DXB190
ASSEMBLING
Top plate tightening procedure

72 With a torque wrench, tighten in a criss---cross


pattern the 8 nuts to 600 Nm.

6 2 8 4

5 3 7 1

600 Nm

Mark

74 Make mark on the plate for each nut position.

73 Count 4 flats in an anticlockwise


direction and mark the nut.

Anticlockwise 75 Make mark on the tool socket.

WS 157 DOOSAN
DXB190 06 / 2011
ASSEMBLING

76 Tighten in a criss---cross pattern the 8 nuts for


2 flats (120° ).
1st Cycle
Plate mark

After Before 6 2 8 4

5 3 7 1

77 Tighten in a criss---cross pattern the 8 nuts for


2 flats (120° ).

2nd Cycle

After

6 2 8 4
Before
5 3 7 1

OK
The nut mark must be in line with the plate mark.

DOOSAN WS 158
06 / 2011 DXB190
ASSEMBLING

78 Mount the 4 O’rings inside the retaining


lock grooves.

79 Sling and lift the breaker.

80 Mount the retaining lock.

81 Drive the pin in.

82 Place the breaker on the blocks.

WS 159 DOOSAN
DXB190 06 / 2011
ASSEMBLING

83 With a sling, mount the tool.

150 daN

Grease

84 Drive the 2 retaining pins in.

DOOSAN WS 160
06 / 2011 DXB190
ASSEMBLING

85 Mount the retaining lock.

86 Drive the pin in.

WS 161 DOOSAN
DXB190 06 / 2011
ASSEMBLING

STROKE ADJUSTMENT

High frequency
1

21
2

OR 100 Nm

1 Low frequency

3/16”

100 Nm

DOOSAN WS 162
06 / 2011 DXB190
INFLATING PROCEDURE

BACK HEAD NITROGEN INFLATING


PROCEDURE

IMPORTANT !

NITROGEN ONLY

Before inflating :
The strike piston must be imperatively in
down position, the tool (rod) must not
push the piston upward (contact) or,
dismantle the tool (rod).

For safety reasons :


Do not stay close to the tool (rod),
during the inflating operation.

WS 249 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

ACCORDING TO THE MODEL

See pages WS 251 to WS 258

See pages WS 259 to WS 266

DOOSAN WS 250
06 / 2011 DXB190
INFLATING PROCEDURE

1 Unscrew the plug with hexagonal key (3/16”)


and remove it.

3/16”

Only in case of dismantling :

DANGER !
The back head is full of nitrogen.

Ø 5 ±1 2 Insert and push the pin to empty the back head.

3 Check the presence of the o’ring


on the adaptor inflating tool.

WS 251 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

4 Put in place and screw the inflating tool.

24

5 Screw in with an open wrench.

6 Connect the nitrogen bottle to


the hose.

DOOSAN WS 252
06 / 2011 DXB190
INFLATING PROCEDURE

7 Turn on the nitrogen bottle stop cock.

8 Using the pressure regulator


valve, that the nitrogen gas
penetrates into the back head.

First inflating : 9 to 15 otherwise go to step 16

10 bar
9 Adjust the pressure to 10 bar.

WS 253 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

10 Turn off the pressure regulator valve.

11 Turn off the nitrogen bottle stop cock.

12 Disconnect the hose from the


regulator valve, to drain out the
oxygen contents into the back head.

Pay attention at the hose movement.

DOOSAN WS 254
06 / 2011 DXB190
INFLATING PROCEDURE

13 Reconnect the hose on the regulator


valve.

14 Turn on the nitrogen bottle stop cock.

15 Turn on the regulator valve.

16 bar
16 Adjust until the specified pressure.
See TABLE (pressure according
to the temperature).

WS 255 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
3 mn
17 Wait 3 mn to stabilyze the
pressure.

18 Close the nitrogen bottle stop cock.

19 Reset the pressure regulator valve


to zero.

20 Disconnect the hose :


1) from the inflating device
2) screw the plug

21 Dismount the inflating device.

DOOSAN WS 256
06 / 2011 DXB190
INFLATING PROCEDURE

22 Put the device and the hose away.

23 Fill inflating device valve with “silicon”


in spray to check the valve leak.

24 Check that there are no bubbles


formed on the surface.

WS 257 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

25 Clean correctly.

26 Put back the lock plug.

3/16”

27 Tighten with a wrench torque.

37 Nm

DOOSAN WS 258
06 / 2011 DXB190
INFLATING PROCEDURE

1 Unscrew the plug with hexagonal key (3/16”)


and remove it.

3/16”

DANGER !
The back head is full of nitrogen.

Ø 5 ±1 2 Insert and push the pin to empty the back head.

Turn the control knob completely in an


3 anticlokwise direction.
+

WS 259 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

4 Put in place and screw the inflating tool


without touching the control knob.

15

5 Screw in with an open wrench.

6 Close the draining cock.


+

DOOSAN WS 260
06 / 2011 DXB190
INFLATING PROCEDURE

7 Connect the nitrogen bottle to


the hose.

8 Turn on the nitrogen


bottle plug cock.

10 bar 9 Using the pressure reducing


valve, to adjust the pressure to
10 bar.

10 Screw the control knob


clokwise. The nitrogen gas
penetrates into the back head.

WS 261 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE
11 Turn off the nitrogen bottle plug cock.

Turn the control knob completely in


12
the anticlokwise direction.

13 Open the draining cock.

+
+

14 Reset the pressure


reducing valve to zero.

15 Close up the draining cock.

DOOSAN WS 262
06 / 2011 DXB190
INFLATING PROCEDURE

16 Turn on the nitrogen


bottle plug cock.

16 bar 17 Adjust until the specified pressure.


See TABLE (pressure according
to the temperature).

18 Screw the control knob clokwise.


The nitrogen gas penetrates into
the back head.

3 mn

19 Wait 3 mn to stabilyze the


pressure.

20 Close the nitrogen bottle


plug cock.

21 Reset the pressure


reducing valve to zero.

WS 263 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

22 Turn the control knob completely


in an anticlokwise direction.

23 Open the draining cock.


+
+

24 Disconnect the hose.

25 Dismount the inflating device.

DOOSAN WS 264
06 / 2011 DXB190
INFLATING PROCEDURE

26 Replace the device into the tool box.

27 Fill inflating device valve with “silicon”


in spray to check the valve leak.

28 Check that there are no bubbles


formed on the surface.

WS 265 DOOSAN
DXB190 06 / 2011
INFLATING PROCEDURE

29 Clean correctly.

30 Put back the lock plug.

3/16”

31 Tighten with a wrench torque.

37 Nm

DOOSAN WS 266
06 / 2011 DXB190
INFLATING PROCEDURE
BACK HEAD INFLATING TABLE
(depend of the temperature of the back head surface)

Nitrogen pressure setting (in bar)

Temperature in ° C -- 20 -- 10 0 10 20 30 40 50 60 70

Breaking mountain A 13 13,5 14 14,5 15 15,5 16 16,5 17 17,5

Secondary breaking stone B


9 9,5 10 10,5 11 11,5 12 12,5 13 13,5
Breaking building C

13.5 bar 15 bar

A A

9.5 bar 11 bar

B B

9.5 bar 11 bar

C C

WS 267 DOOSAN
DXB190 06 / 2011
TOOLING

86693983 86485802

ORFS
86718590
M 20 HM6

86677846

Ø 25 -- lg : 250 mm

86705332

86704624

86697851

86626017

(tool case delivered with each breaker)


86480597

1’’

1’’ 1/2

70 86697844

DOOSAN WS 268
06 / 2011 DXB190
TOOLING

T1
Ø 238 ' 240

150 ' 155

T2
Ø 300 ' 350

These 3 tools are in steel Ø 40 ' 60

800

T3 58

70¦ 5 138

WS 269 DOOSAN
DXB190 06 / 2011
TOOLING

Support
To make

Ø 132

U : 175 x 70
Ø 135

100 4 x Ø 30

200

270

600
600

DOOSAN WS 270
06 / 2011 DXB190
TOOLING

86697943
To order

Ø 132

90
+0,2
Ø 95,2 0

Ø 135

100

0
--- 0,2
Ø 95

WS 271 DOOSAN
DXB190 06 / 2011
BREAKER