CARE & OPERATION

(MAY’13)
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INDEX

Sl.
No. Description
h Page No.

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1 T CLAMP WELDING PROCEDURE 2

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2 ROCK BREAKER MAINTENANCE SCHEDULE 3
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3 GREASING PROCEDURE
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4 ROCK BREAKER BREATHER

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HYDRAULIC OIL FLUSHING PROCEDURE 6

6 v
FRONT HOSES INSTALLATION PROCEDURE 7-8

7 THROUGH BOLTS TORQUING b 9

8 PERMISSIBLE WEAR LIMITS

n 10

9 GAS CHARGING PROCEDURE

m 12-15

9
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OPERATION –DOs AND DON'Ts 16 - 21

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10 LONG STORAGE OF BREAKER ASSY.. 21
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2

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 T CLAMP WELDING PROCEDURE (all models)

Similar gap between the edges to be maintained while welding bracket for Solenoid

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 ROCK BREAKER MAINTENANCE

Item Commissio 3 8 50 125 150 250 500 600 1000

ning Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs
Greasing -Chisel
,Chisel Pin

Air Valve Cleaning

Flushing of oil

Oil Leakage -
Checking
Through Bolt
Torque Checking -
Loosening
Gas Pr. Checking

Chisel pin wear

checking & Face
changing
Wear limit
checking between
Chisel & Front
Cover
Seal Kit
Replacement on
Rock Breaker to
be carried out.
Replacement
Interval of Hyd
Filter (Standard
type)
Replacement
Interval of Hyd
Filter (High
Performance type)
Replacement
interval of Hyd Oil
with Standard
(Normal)Filter
Replacement
interval of Hyd Oil
with High
Performance Filter

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 GREASING PROCEDURE

Greasing interval: - every 3 hours.

During Greasing following steps need to be followed

1) Place the Breaker vertically (90 Degree with respect to the horizontal surface) with chisel firmly
pressed inside the front head.
 Note:- Never ever place the rock breaker in horizontal position while greasing.
In case of rock breaker positioned horizontally, the grease shall pass through the passage
provided in front head, cylinder & head cap and shall reach the Breather. This shall result in
chocking of the Breather.
2) Pump the grease with grease gun through the nipple as per model given.
3) When the Breaker is equipped with a new chisel apply the grease first and then mount the same.
4) Insufficient lubrication to the chisel shortens the life of front cover, chisel pins and chisel.
5) Grade of grease: lithian EP2.

B10, B20, B140, B210, B300, B450 B600

B30, B40, B180 B230, B360 B800
Model
B50, B70, B250
B90
Grease gun
application 10 15 20 25 30 35
(No. of Pumps)

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 ROCK BREAKER BREATHER
Location : Air breather assembly is provided on the head cap.

Function / Purpose: The air breather allows free passage of air through it and sends to front head chamber
during the operation of rock breaker. The fresh air ejects dust particles outside of front head thereby
preventing contaminants to enter the Impact chamber.

Failure / chocking of Breather results in;

1) Piston - cylinder Scoring
2) Contamination of Hydraulic oil resulting in failure of Hydraulic pumps and motors.

Preventive Maintenance : Breather should be cleaned every 50 hrs of operation.

Below photo snaps are of Air Breather in dismantled condition & of air breather chocked with
grease

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 HYDRAULIC OIL FLUSING PROCEDURE
When Required ?
1) Flushing needs to be carried out during installation of the New rock breaker.
2) Flushing needs to be carried out every time when Rock breaker is installed after removal of the
bucket.

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 FRONT HOSES INSTALLATION PROCEDURE

1. Close both stop valves

2. Mount breaker onto the excavator

3. Install both hoses on breaker to ensure no twisting at the crimp joint.

 After using hand, you can use spanner with proper torque

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 WRONG RIGHT
4. Open both stop valves

5. Start the operation

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 THROUGH BOLTS TORQUING

1. Step-1: Apply 90 kgf-m to T/Bolt of the Breaker.

2. After giving 90 kgf-m torque to T/Bolt, rotate in degree (°) clock wise as per given step-2 to achieve
specified torque.

3. After torque -- Put indication mark on the T/Bolt nut and Head Cap so that the loosening of T/bolt
in due course can be checked through the Window in the Bracket assy.

Specified Step -1 Step-2

Torque (kg- (Give torque Rotate in Rotating degree
Model m) 90 Kgf-m to Degree(°) as
t/bolt ) per br. model °
B70 120 90 25
B140 160 90 45
B210/B230 300 90 110
B300/360 540 90 160

B450 580 90 170

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Permissible wear limits of Front cover bush –Between ID of Front cover and Chisel-
OD.

When the increase in clearance between the chisel and front cover bush beyond specified values, It is
strongly recommended to replace Front Cover Bush & Thrust Ring. Exceeding wear limits value may
damage other component parts such as --
1) Piston and Cylinder scoring
2) Chisel breakage
3) Chisel Pin/Stop pin.

Breaker Std Chisel std Front Std clearance Limit of use-

Model OD (mm) cover ID (mm) between from cover clearance between
(Tolerance (Tolerance - 0.7 ID and Chisel OD chisel OD & Front
+0.5 ~0.6) ~0.9) (mm), in new br. cover ID (MM)
1.2 Min. ~ 1.5
B50 70 70 Max. 4
1.2 Min. ~ 1.5
B70 78 78 Max. 5
1.2 Min. ~ 1.5
B140 105 105 Max. 5
1.2 Min. ~ 1.5
B210 135 135 Max. 6
1.2 Min. ~ 1.5
B360 155 155 Max. 9

Fig:- Excessive wear of front bushes

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 Head Cap--Gas charging procedure

 Head Cap Pressure Table :-

Rock Breaker Model B70 B140 B210 B230 B360 B450

Head Cap Gas Pressure (Kg/Cm2) 12 12 11 11 11 11

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Accumulator--- Gas charging procedure

 Accumulator Pressure Table :-

Rock Breaker Model B230 B250 B300 B360 B450

Accumulator Gas Pressure Kg/Cm2) 52 52 52 52 52

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15
 Rock Breaker Operation Method
.
1) Proper thrust: - To break effectively, a proper thrust force has to be applied to the
breaker. If a thrust
Is insufficient, the hammering energy of the piston will not be sufficient for breaking rocks.
The hammering force is transferred to the breaker body, arm and boom of the base
machine as a result damages the structure of the machine. On the other hand, if the thrust
force is excessive or when breaking is performed with boom of the base machine raised,
the machine may suddenly tilt toward the moment rocks are broken and the breaker body
may violently hit against rocks to result in Damage. If hammering is performed under such
a condition, vibrations may also be transmitted to the tracks; hammering in such a manner
should be avoided to also protect the tracks parts

3) Direction of thrust: - Apply a thrust in a straight line with the tool. Place the tool on
a rock with the hammering side as vertically as possible. If the hammering side is
oblique, the tool may slip during hammering, causing the chisel and piston to break,
or seized. When breaking, select the point of a rock on which hammering can
perform stably and fully.

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Precaution during operation:-

A) Stop the operation as soon as the hoses vibrate excessively. Check to see if the high
and low pressure hoses of the breaker vibrate excessively. If so, the accumulator may be
defective.
B) Visually inspect whether there is a surplus of tool appearance, during operation as
illustrated.

C) As soon as rocks are broken, the hammering should be stopped .If the breaker
operates without surfaces the failure will lead to following parts –chisel pin .This condition
applies when the ABF off condition.

D) Do not move rocks.- Do not roil or throw down a rock with the end of the chisel or the
side of the bracket using the oil pressure for the base machine boom, arm, bucket, swing
or traveling because the bolts of breaker may
Be broken, the bracket damaged, the chisel broken or scuffed, and the boom or arm
damaged.

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 E) Do not use the chisel tool as a lever.- When a rock is broken by using the tool as a
lever , the bolts and
Chisel may be broken.

F) Do not continue to hammer for more than 30 seconds on a same point. When rocks
are hard, do not hammer the same place for such a long time to exceed one minute but
change the point to be hammered. The long time
Hammering raises the oil temperature to result in the damaged accumulator and cause the
chisel to be excessively worn.

G) On a hard, large rock, start breaking at the end point. Beginning to hammer at the
crack or the end will enable even a big rock to be broken comparatively easily.

H) Operate the breaker at a proper engine speed , . Raising the engine speed more than
Necessary does not increase the hammering force but raises the oil temperature to result
in the damaged equipment.

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I) Do not operate the breaker in water and mud. If not, the piston or the similar
components may be rusted to result in the permanently damaged breaker. In case
of operation in or under the water, buy underwater operation kit separately .

J) Do not hammer with the cylinders extended to the end of stroke .When a rock is broken
with base machine cylinder moved to the end, (the cylinder extended or retracted fully),
the cylinder and each part of the base machine may be damaged.

K) Do not install a wire to the breaker, bracket and chisel for slinging an object, the
Breaker, bracket and chisel may be damaged; further, such an action is very dangerous in
operation. Never lift or transport loads with the hydraulic breaker

L) The boom of the excavator or arm can be damaged if not operated correctly. Please be
aware of the location of the Breaker’s chisel while operating the breaker.
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M) Warm up the base machine engine from five to twenty minutes and then operate the
breaker.. At temperatures below minus 20℃, the hydraulic oil must be warmed up before
operating. The hydraulic breaker and excavator do not begin to perform at full capacity
until an operating temperature has been reached at 60 ℃ . If the breaking operation is
done at low oil temperature without warming up the engine, the breaker parts such as the
piston and seals may be damaged..
N) As the breaker, side bolts, nuts, pipe and hose fittings may be loosened due to
vibration, check for looseness before starting the operation and after finishing the
operation. The bolts and nuts can easily become loosened, which is the cause of severe
damage to several component parts. Thus, check torque of bolts periodically

O) When a tool is used for many hours, it may be worn or got burs. In such a case,
remove them with a grinder.
Further, when the chisel end is worn, the chisel may also slip easily. Therefore, it is
advisable to grind smooth. However, as the chisel is repaired many times, the hardened
layer is removed and the chisel easily worn.
In such a case, replace with new chisel.

P) When you start breaking a rock, you should select a point on which the rock will be
broken away at best within 30 seconds. If the operating will not be in that case, the
advance must be either reduced or restarted at a different point.
Q) Chisel should always be at right-angle to the surface of the material. If not, the
hydraulic breaker wears more quickly, eventually leading to permanent damage.

Q) Gently rocking the hydraulic breaker backward and forward (max.5°) allows dust to
Escape, but it will dampen the percussive power of the chisel. However, rocking at angles
greater than 5°may cause bending strain resulting in damage to chisel and hydraulic
breaker.
R) Using the hydraulic breaker as a crowbar may cause chisel breakage. So it should not
be used as a crow bar .

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S) Never drive chisel into the material If the advance is too much and the breaker is not
rocked to release the dust, chisel will be driven into the material, causing the tip to glow
red hot and become soft.

T) If water penetrates the percussion chamber of the hydraulic breaker, a pressure wave
builds up with each stroke which will damage the stripper and the seals of the breaker and
cause the lower part of the piston to rust.

U) Check the oil temperature constantly to ensure it does not exceed 80℃. If higher
temperature is measured in the tank, an oil cooler must be fitted. Only use hydraulic oils
with adequate viscosity.

V) Make sure there is a sufficient amount of oil in the tank at all times. If the hydraulic oil is
dirty, the valve and piston will be operated improperly.

Long Storage of Breaker assy.

1. Store breaker in dry area under shade.

2. Chisel should be removed and nitrogen gas should be released.

3. Apply grease on the piston face and Front Bushings.

4) Put the breaker vertically on the front head side on wooden square bars to avoid

seal failure.

5) Replace the cylinder seal kit if the breaker is kept idle for a long period.

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